Emerson VSG, VSSG User Manual

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VSG/VSSG compressor unit

Installation, operation & maintenance manual

VSG/VSSG Standard Vilter Warranty Statement

Seller warrants all new single screw gas compression units and bareshaft single screw compressors

manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period

of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of

installation at the end user’s location, whichever occurs ﬁ rst.

If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product

shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation

and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice

of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by

Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses

prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product

(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by

written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,

incidental, or special damages arising out of a breach of warranty.

This warranty is only applicable to products properly maintained and used according to Seller’s

instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,

misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond

rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller

or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not

warrant that any equipment and features meet the requirements of any local, state or federal laws or

regulations. Products supplied by Seller hereunder which are manufactured by someone else are not

warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products

that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by

warranty.

THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the products, whether in writing or made orally by Seller or Seller’s agents,

speciﬁ cations, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used

in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be

construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or

suitability of the products shall not be construed as an express warranty unless conﬁ rmed to be such in

writing by Seller.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Important Message

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw Compressors. Following these instructions will result in a long life of the compressor with satisfactor y operation.

The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.

A compressor is a positive displacement machine. It is designed to compress gas. The compressor must not be subjected to liquid carry over. Care must be exercised in properly designing and maintaining the system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot warrant equipment damaged by improperly protected or operating systems.

Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage noted should be reported immediately to the Transportation Company. This way, an authorized agent can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilter representative or the home office should be notified of any claim made.

All inquires should include the Vilter sales order number, compressor serial and model number. These can be found on the compressor name plate on the compressor.

All requests for information, services or parts should be directed to:

Vilter Manufacturing LLC

Customer Service Department

P.O. Box 8904

5555 South Packard Ave

Cudahy, WI 53110-8904 USA

Telephone: 1-414-744-0111

Fax:1-414-744-3483

e-mail: info.vilter@emerson.com

Equipment Identification Numbers:

Vilter Order Number: _______________________Compressor Serial Number: _________________ Vilter Order Number: _______________________Compressor Serial Number: _________________ Vilter Order Number: _______________________Compressor Serial Number: _________________ Vilter Order Number: _______________________Compressor Serial Number: _________________

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section Title Section Number

VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... i

Important Message................................................................................................................................ii

Section 1 • General Information

How To Use This Manual .........................................................................................................................1-1

Gas Compressor Unit Model Designations ..............................................................................................1-2

System Unit Identification .....................................................................................................................1-3

Compressor Unit Component Identification ........................................................................................... 1-4

Piping & Identification Component Tags ................................................................................................. 1-7

Symbols and Identification .....................................................................................................................1-8

Section 2 • Theory of Operation

Gas Flow ................................................................................................................................................2-1

Oil Life and Oil Flow ................................................................................................................................2-1

Oil Pressure Regulating ..........................................................................................................................2-2

Control System ......................................................................................................................................2-2

RTDs and Pressure Transducers .............................................................................................................. 2-2

Section 3 • Installation

Delivery Inspection ................................................................................................................................3-1

Rigging and Lifting ................................................................................................................................. 3-1

Short Term Storage Recommendations ..................................................................................................3-2

Long Term Storage Recommendations ...................................................................................................3-2

Compressor Motor .....................................................................................................................3-2

Air Cooled Oil Coolers ................................................................................................................ 3-3

Compressor Unit Inspections Prior to Stoarge or Installation .................................................................. 3-3

Recommended Onsite Tools .................................................................................................................. 3-3

Long Term Storage Log ..........................................................................................................................3-4

Foundation ............................................................................................................................................3-5

Piping ..................................................................................................................................................3-10

Header Piping and Drains ...........................................................................................................3-10

Remote Air Cooled Oil Cooler Piping ..........................................................................................3-10

General Installation Guideline for Multiple Air Coolers Installed in a Common Area ................................ 3-12

Free Flow ...................................................................................................................................3-12

One Fan Diameter ...................................................................................................................... 3-12

Intake Velocity ...........................................................................................................................3-12

Hot Air Recirculation ..................................................................................................................3-14

Pressure Testing ..................................................................................................................................... 3-16

Initial Oil Charging .................................................................................................................................3-16

Using Non-Vilter Oils .................................................................................................................. 3-16

Unit Oil Charging and Priming .................................................................................................... 3-16

Priming Oil Cooler (Shell and Tube)and Piping............................................................................3-16

Priming Compressor and Oil Filters ............................................................................................ 3-18

Priming Remote Oil Cooler and Piping (Initial Oil Charging) ........................................................3-20

Priming Compressor and Oil Filters ............................................................................................ 3-21

Pre Start-Up ...........................................................................................................................................3-22

Start-Up .................................................................................................................................................3-24

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

TOC - 1

Table of Contents

Section Title Section Number

Section 4 • Operation

Oil Inspection ........................................................................................................................................4-1

Dual Oil Filters........................................................................................................................................4-1

Control System Calibration ....................................................................................................................4-2

Starting, Stopping and Restarting the Compressor ................................................................................4-2

Calibrate Slide Valve Actualors ...............................................................................................................4-2

Oil Temperature Control Valve (Oil Mixing Valve) Operation ...................................................................4-7

Manual Override ........................................................................................................................4-8

Purging with Dry Nitrogen ..................................................................................................................... 4-9

Purging with Dry Gas .............................................................................................................................4-11

Coalescing Oil Return Line Setup ............................................................................................................ 4-14

Section 5 • Maintenance/Service

Maintenance and Service Schedule ........................................................................................................ 5-1

Maintaining Proper Operation ................................................................................................................5-2

Compressor Unit Isolation for Maintenance/Service ...............................................................................5-3

Compressor Unit Leak Check ..................................................................................................................5-3

Oil System Components ......................................................................................................................... 5-4

Oil Sampling...............................................................................................................................5-4

Oil Charging ...............................................................................................................................5-5

Oil Draining ................................................................................................................................5-6

Oil Filter Replacement ................................................................................................................5-6

Coalescing Oil Filter Replacment ................................................................................................. 5-8

Oil Pump Strainer .......................................................................................................................5-9

Drive Coupling (Form-Flex BPU) Installation ...........................................................................................5-10

Drive Center Member (Form-Flex BPU) Installation and Alignment .........................................................5-11

Drive Coupling (Form-Flex BPU) Removal ............................................................................................... 5-13

Drive Coupling (Type C Sure-Flex) Replacement ..................................................................................... 5-13

Compressor Replacement ...................................................................................................................... 5-14

Compressor Bearing Float Inspections ...................................................................................................5-16

Gate Rotor Float and Gate Rotor Bearing Float Inspection .......................................................................5-17

Gate Rotor and Support Clearance ......................................................................................................... 5-19

Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except VSG 301-701 Compressors) .... 5-21

Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY) ...................................................5-24

Gate Rotor Disassembly .........................................................................................................................5-26

Gate Rotor Blade Removal/Installation ....................................................................................... 5-26

Gate Rotor Thrust Bearing Removal/Installation .........................................................................5-27

Gate Rotor Roller Bearing Removal/Installation ........................................................................... 5-27

Slide Valve Actuator Assembly Replacement .......................................................................................... 5-28

Command Shaft Assembly Replacement ................................................................................................5-29

Command Shaft Seal Replacement .........................................................................................................5-29

Section 6 • Troubleshooting

Table 6-1. Slide Valve Actuator Troubleshooting Guide ........................................................................... 6-1

Table 6-2. Slide Valve Actuator LED Blink Codes ......................................................................................6-3

Table 6-3. Troubleshooting Guide - General Problems & Solutions ..........................................................6-5

TOC - 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

List of Tables and Figures

Section Title Section Number

Section 7 • Warranty and Parts

Warranty Claim Processing .................................................................................................................... 7-1

On Site Service Support ......................................................................................................................... 7-1

Remanufactured Bare Shaft Compressors Process ..................................................................................7-2

Explanation of Rebuild Levels .....................................................................................................7-2

Bare Shaft Compressor Description ............................................................................................7-2

Appendices

Appendix A Torque Specifications ......................................................................................................A

Appendix B Motor (Compressor) General Storage Instructions .......................................................... B

Appendix C Oil Analysis Report .......................................................................................................... C

Appendix D Recommended Header Piping ........................................................................................D

Appendix E Recommended Remote Air Cooled Oil Cooler Piping .......................................................E

Table/Figure Section Number

Tables

Table 3-1. Long Term Storage Compressor Hardware .............................................................................3-2

Table 3-2. Maximum Allowable Flange Loads ......................................................................................... 3-11

Table 4-1. Command Shaft Rotation Specifi cations ................................................................................4-6

Table 5-1. Maintenance/Service Schedule ..............................................................................................5-1

Table 5-2. Oil Filter Elements and Compressor Models ............................................................................5-6

Table 5-3. Shaft and Hub Distances ........................................................................................................5-10

Table 5-4. Hub Clamp Bolt and Set Screw Torque Specifi cations ............................................................. 5-12

Table 5-5. Disc Pack Installation Torque Specifi cations ...........................................................................5-12

Table 5-6. Clamping Bolts and Set Screw Torque Specifi cations..............................................................5-14

Table 5-7. Maximum Bearing Float (Compressor Shaft) ..........................................................................5-17

Table 5-8. Gate Rotor Float .....................................................................................................................5-18

Table 5-9. Gate Rotor Tool Sets ...............................................................................................................5-21

Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2) ...............................................................6-1

Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2) ........................................................................6-3

Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) ..............................................6-5

Figures

Figure 1-1. Gas Compressor Unit Model Designation .............................................................................1-2

Figure 1-2. Gas Compressor Unit Components .......................................................................................1-4

Figure 2-1. Gas Compressor Unit P&ID ...................................................................................................2-1

Figure 3-1. Rigging and Lifting Points .....................................................................................................3-1

Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View ................................................3-5

Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View ...............................................3-6

Figure 3-4. Interior Foundation Isolation ................................................................................................ 3-6

Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View ................................................3-7

Figure 3-6. Housekeeping Pad Dimension Detail - Top View ...................................................................3-9

Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers ............................................3-9

Figure 3-8. Concrete Pad Housekeeping Detail .......................................................................................3-10

Figure 3-9. Maximum Allowable Flange Loads ........................................................................................3-11

Figure 3-10. Installation of Coolers - One Fan Diameter Next to Building ................................................ 3-12

Figure 3-11. Leg Height ..........................................................................................................................3-13

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

TOC - 3

List of Tables and Figures

Table/Figure Section Number

Figure 3-12. Installation of Coolers - Next to Buildling ............................................................................3-13

Figure 3-13. Discharge Elevation of Coolers ............................................................................................ 3-15

Figure 3-14. Cooler Placement and Spacing ............................................................................................ 3-15

Figure 3-15. Oil Operating Levels ...........................................................................................................3-17

Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain and Oil Filter Shut-Off Valves ...........................3-17

Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping .......................................................................3-18

Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping ............................................ 3-19

Figure 3-19. Priming Remote Oil Cooler and Piping ................................................................................3-20

Figure 3-20. Priming Compressor and Oil Filters ..................................................................................... 3-21

Figure 4-1. Oil Operatiing Levels ............................................................................................................. 4-1

Figure 4-2. Actuator Assembly ............................................................................................................... 4-3

Figure 4-3. Menu Screen and Slide Calibraiton Button (Compact Logix PLC) ...........................................4-4

Figure 4-4. Slide Valve Calibraiton Screen (Compact Logix PLC) .............................................................. 4-5

Figure 4-5. Photo-chopper .....................................................................................................................4-5

Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve) .................................................................. 4-8

Figure 4-7. PLC Main Screen ................................................................................................................... 4-9

Figure 4-8. Suction Bypass Valve and Equalizing Solenoid ....................................................................... 4-10

Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve .......................................................... 4-10

Figure 4-10. Customer Purge Line .......................................................................................................... 4-11

Figure 4-11. PLC Main Screen ................................................................................................................. 4-12

Figure 4-12. Suction Bypass Valve and Equalizing Solenoid ..................................................................... 4-13

Figure 4-13. Suction Oil Charging Valve .................................................................................................4-13

Figure 4-14. Coalescing Oil Return Line .................................................................................................. 4-14

Figure 5-1. Suction Bypass Valve (Manual) Location (1 of 2) .................................................................... 5-2

Figure 5-1. Suction Bypass Valve (Equalizing Solenoid) Location (2 of 2) .................................................5-3

Figure 5-2. Oil Analysis Kit ...................................................................................................................... 5-4

Figure 5-3. Suction Oil Charging, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves ............................5-5

Figure 5-4. Oil Filter Assemblies (Single and Dual) ..................................................................................5-6

Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves .............................................................................. 5-7

Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly ................................................5-8

Figure 5-7. Oil Pump Strainer and Drain Valve ........................................................................................ 5-9

Figure 5-8. Hub Distance (Axial Spacing) ................................................................................................5-11

Figure 5-9. Angular Alignment and Parallel Offset ..................................................................................5-12

FIgure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown) ................5-15

FIgure 5-11. Bearing Axial Float Inspection (Compressor) .......................................................................5-16

FIgure 5-12. Bearing Radial Float Inspection (Compressor) .....................................................................5-17

FIgure 5-13. Gate Rotor Float ................................................................................................................. 5-17

FIgure 5-14. Gate Rotor Bearing Float ..................................................................................................... 5-18

FIgure 5-15. Gate Rotor and Support Clearance - Minimum Clearances .................................................. 5-19

FIgure 5-16. Gate Rotor and Support Clearance - Measuring ................................................................... 5-20

FIgure 5-17. Gate Rotor Assembly Removal and Tools ............................................................................5-22

FIgure 5-18. Gate Rotor Assembly Removal ............................................................................................5-22

FIgure 5-19. Gate Rotor Assembly and Tools ...........................................................................................5-23

FIgure 5-20. Gate Rotor and Shelf Clearance ........................................................................................... 5-23

FIgure 5-21. Gate Rotor Assembly Breakdown ........................................................................................5-24

FIgure 5-22. Gate Rotor Thrust Bearing .................................................................................................. 5-25

FIgure 5-23. Gate Rotor and Shelf Clearance ........................................................................................... 5-25

FIgure 5-24. Gate Rotor Blade Assembly .................................................................................................5-26

FIgure 5-25. Gate Rotor Blade Installation .............................................................................................. 5-26

FIgure 5-26. Gate Rotor Thrust Bearing .................................................................................................. 5-27

FIgure 5-27. Thrust Bearing Installation .................................................................................................. 5-27

FIgure 5-28. Roller Bearing Assembly ..................................................................................................... 5-28

FIgure 5-29. Command Shaft Seal ..........................................................................................................5-29

FIgure 5-30. Command Shaft Seal Installation ........................................................................................5-30

TOC - 4

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 1 • General Information

How To Use This Manual

This manual contains instructions for gas compressor units. It has been divided into eight sections:

Section 1: General Information

Section 2: Theory of Operation

Section 3: Installation

Section 4: Operation

Section 5: Maintenance & Service

Section 6: Troubleshooting

Section 7: Warranty and Parts

Appendices

It is highly recommended that the manual be reviewed prior to servicing system parts.

Figures and tables are included to illustrate key concepts.

Safety precautions are shown throughout the manual. They are deﬁ ned as the following:

NOTICE - Notice statements are shown when there are important information that shall be followed. Not following such notices may result in void of warranty, serious ﬁ nes, serious injury and/or death.

WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in serious injury and/or death.

CAUTION - Caution statements are shown when there are potentially hazardous situations, if not avoided, will result in damage to equipment.

NOTE - Notes are shown when there are addtional information pertaining to the instructions explained.

Additional installation, operation and maintenance instructions can be found in the associated software manual and bareshaft compressor manual.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1 – 1

Section 1 • General Information

Gas Compressor Unit Model Designations

The compressor unit model designation can be found on the nameplate. For nameplate location, see Component Identiﬁ cation on section page 1-4.

VSG-601-VVR-L-HP-VFD-36H-NEC-ST-WTR

1234567 8 9 10

Figure 1-1. Gas Compressor Unit Model Designation

1. Compressor Model

VSG = Vilter Single Screw Compressor

VSSG = Vilter Single Screw Compressor

(Compressor models 291, 341, 451 & 601 - these are 240mm diameter rotors with counter clockwise rotation)

VRSG = Vilter Twin Screw

2. Size

CFM - Nominal CFM displacement of the compressor at 3600 rpm

3. Slide Arrangement

VVR = Variable Volume Ratio; Parallex™

4. Gas Compressed

L = Landﬁ ll Gas

D = Digester Service Site Application

N = Natural Gas (Primarily Methane)

G = Other Gas Type

5. Application

HP = High Stage with Oil Pump

HN = High Stage no Oil Pump

7. Separator Type

16 = 16 inch diameter 36 = 36 inch diameter

20 = 20 inch diameter 42 = 42 inch diameter

24 = 24 inch diameter 48 = 48 inch diameter

30 = 30 inch diameter 54 = 54 inch diameter

H = Horizontal V = Vertical

SH = Special Horizontal SV = Special Vertical

8. Economizer

NEC = No Economizer, Economizer Ports Plugged

HEC = Holes drilled in Economizer Plug for Oil or Unloading

9. Oil Cooler

PLT = Plate

ST = Shell and Tube

REM = Remote

10. Oil Cooling Medium

REF = Refrigerant

WTR = Water

GL = Glycol

AIR = Air

6. Driver

VFD = Variable Frequency Drive

EMD = Electric Motor Drive

ENG = Engine Drive

1 – 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 1 • General Information

System Unit Identiﬁ cation

To keep deﬁ nitions of units simple and consistent, Vilter has deﬁ ned the following three:

• Bare Shaft Compressor

• Compressor Unit

• Package Unit

Bare Shaft Compressor

A bare shaft compressor is just the compressor with no coupling and motor nor foundation.

Compressor Unit

A compressor unit consists of the bare shaft compressor with the coupling, motor, oil separator, frame, micro-controller system and oil system. A compressor unit typically a single screw compressor unit, is not mounted on a structural steel base.

Package Unit

A package unit is a complete system mounted on a structural steel base with interconnecting piping.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1 – 3

Section 1 • General Information

Compressor Unit Component Identiﬁ cation

Each gas compressor unit may differ, but below are typical components that can be found on each unit.

1 - Motor

2 - Coupling

3 - Suction Strainer

4 - Suction Check Valve

5a - Suction Stop Valve

5b - Suction Stop Butterﬂ y Valve

(Typically Shipped Loose)

6 - Compressor

7 - Discharge Pipe

8 - PLC Panel

9 - Block & Bleed Assembly

10 - Oil Pump

11 - Oil Heater

12 - Oil Separator

13 - Oil Temperature Control Valve

(Oil Mixing Valve)

14 - Oil Pump Strainer

15 - Oil Sight Glass

16 - Oil Filter

(Optional Dual Oil Filters Shown)

23 4 5a

17 - Discharge Connection

18 - Oil Separator Inspection Port

19 - Thermal/Acoustic Oil Separator

Blanket

(Optional Per Application)

20 - Nameplate

21 - Heat Trace Insulation

(Optional Per Application)

22 - Frame

23 - Oil Cooler (Shell and Tube Heat

Exchanger)

Figure 1-2. Gas Compressor Unit Components (1 of 3)

1112141511

1013

1 – 4

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 1 • General Information

2021

Figure 1-2. Gas Compressor Unit Components (2 of 3)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1 – 5

Section 1 • General Information

Component Identiﬁ cation (Continued)

24 - RTD (Oil Filter Outlet)

25 - Pressure Transducer (Oil Injection

Temperature)

26 - Volume Slide Valve Actuator

27 - RTD (Discharge)

28 - RTD (Suction)

29 - Capacity Slide Valve Actuator

30 - Pressure Transducers

(Discharge, Oil Filter Inlet and Outlet)

25 27 28

31 - Block & Bleed Assembly

32 - Remote Oil Cooler (Finned Fan

Heat Exchanger)

33 - RTD (Oil Separator)

1 – 6

Figure 1-2. Gas Compressor Unit Components (3 of 3)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

OUTLET

INLET

Section 1 • General Information

Piping & Identiﬁ cation Component Tags

Use this list to identify components shown in the Piping & Identiﬁ cation Diagram.

A Atmosphere

AN Anode - Sacriﬁ cial

AV Angle Valve

BFV Butterﬂ y Valve

BDV Automatic Blowdown

Valve

BV Ball Valve

C Compressor

CPL Coupling

CRR Cooling Refrigerant Liquid

Return

CRS Cooling Refrigerant Liquid

Supply

CS Carbon Steel or Cold Side

CV Check Valve

CWR Cooling Water Return

CWS Cooling Water Supply

D Drive Motor or Drain

E Heat Exchanger

EQ Equalizing Line

F Fan

FC Fail Closed or Flow

Controller

FG Flow Switch Indicator or

Glass

FI Flow Indicator

FIT Flow Indicating

Transmitter

FO Fail Open

FSI Flow Sight Indicator

FT Flow Transmitter (Blind)

FV Flow Control Valve

(Pneumatic Actuator)

GLV Globe Valve

GTV Gate Valve

HS Hand Switch or Hot Side

HEV Hand Expansion Valve

HV Hand Valve

IA Instrument Air

II Current Indicator

IT Current Transmitter

JB Electrical Terminal Box or

Junction Box

LC Level Control

LE Level Probe

LI Level Indicator or Gauge

LIT Liquid Level Indicating

Transmitter

LO Lube Oil or Lock Open

LP Local Panel

LSH Level Switch High

LSHH Level Switch Shutdown

High High

LSL Level Switch Low

LSLL Level Switch Shutdown

Low Low

LV Level Control Valve -

Pneumatic Actuator

MCC Motor Control Center or

Motor Starter

MV Motor Operated Valve

MGV Manifold Gauge Valve

MI Moisture Indicator

N Nitrogen

NC Normally Closed

NO Normally Open

NV Needle Valve

P Pump or Process

PDI Differential Pressure

Indicator - Gauge

PDIT Differential Pressure

Indicating Transmitter

PDSH Differential Pressure

Switch High

PDSHH Differential Pressure

Switch Shutdown High High

PDSL Differential Pressure

Switch Low

PDSLL Differential Pressure

Switch Shutdown Low Low

PDT Differential Pressure

Transmitter - Blind

PDV Differential Pressure

Control Valve - Pneumatic Actuator

PI Pressure Indicator or

Gauge

PIT Pressure Indicating

Transmitter

PSH Pressure Switch High

PSHH Pressure Switch

Shutdown High High

PSL Pressure Switch Low

PSLL Pressure Switch

Shutdown Low Low

PSV Pressure Safety Relief

Valve

PT Pressure Transmitter

- Blind

PV Pressure Control Valve

QE Heater Element -

Immersion Heater

R Refrigerant

RD Rupture Disc

SDV Automatic Shut-off Valve

SG Sight Glass

SS Stainless Steel or Heat

Exchanger Shell Side

STR Strainer

SV Safety Relief or Slide Valve

SW Selector Switch

TE Temperature Element -

RTD or Thermocouple

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1 – 7

Section 1 • General Information

TI Temperature Indicator or

Thermometer

TIT Temperature Indicator

Transmitter

TRV Transfer Valve - 3-way or

6-way Valve

TS Heat Exchanger Tube Side

TSH Temperature Switch High

TSHH Temperature Switch

Shutdown High High

TTSL Temperature Switch Low

TSLL Temperature Switch

Shutdown Low Low

TT Temperature Transmitter

- Blind

TV Temperature Control

Valve

Symbols and Identiﬁ cations

TW Thermowell

V Vent

VG Gauge Valve

VTRI Venturi

VLV Stop Valve

XV Solenoid Valve

YE Vibration Probe

YSH Vibration Switch High

YSHH Vibration Switch

Shutdown High High

YT Vibration Transmitter

YU Vibration Monitoring

System

YZE Axial Proximitor Probe -

Axial Displacement

YZT Axial proximitor

Transmitter - Axial Displacement

YZU Axial Proximitor

Monitoring System

ZE Position Element

- Positioner

ZI Position Indicator

ZIT Position Indicating

Transmitter

ZT Position Transmitter

- Blind

Use this list to identify components shown in the Piping & Identiﬁ cation Diagram.

3-Way Valve

Angle Valve

Globe Valve

Gate Valve

Butterﬂ y Valve

Ball Valve

Schrader Valve

Pressure Safety Relief

Valve

Spring-Closing Drain

Valve

Block & Bleed Manifold

Solenoid Valve

3-Way Solenoid Valve

Needle Valve

Suction Strainer

Motorized Valve

3-Way Thermostatic Valve

Hand Expansion Valve

Restriction Oriﬁ ce

Rupture Disc

Inlet Pressure Regulating

Valve

Outlet Pressure

Regulating Valve

Differential Pressure

Regulating Valve

Pneumatic Actuator

Control Valve Fail Close

Pneumatic Actuator

Control Valve Open

Diaphragm

Pressure-Balanced

Vilter Venturi Injector

Nozzle

Flange Set

Pipe Reducer

Thermowell

Drive Coupling

Insulation Not by Vilter

Insulation by Vilter

Vibration Absorber

Heater

Heat Trace

1 – 8

Check Valve

Strainer

Diaphragm Actuator

Diaphragm

Low Side Float Valve

Spring-Opposed

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 1 • General Information

High Side Float Valve

Steady-Mount

Bulb & Capillary

Horizontal Tank/Drum

Positive Displacement

Vessel

Pump

Control Panel, Normally Accessible to Operator

Programmable Logic

Control, Local Control Panel, Normally Accessible to Operator

Pneumatic Signal

Thermostatic Expansion

Valve

Pilot Light (Color Inside)

Man-Way Cover

BY VILTER BY OTHERS

Scope of Supply

SV E1

Economizer Regulator

Compressor

Motor

Heat Exchanger

Fan

Vertical Tank/Drum Vessel

Centrifugal Pump

Rotary Pump

Filter

Plate & Frame Heat

Exchanger

Discrete Instrument, Field

Mounted

Discrete Instrument,

Remote, Mount, Normally Accessible to Operator

Discrete Instrument, Local

Rack Mounted, Normally Accessible to Operator

Shared Display/Control,

Field Mounted

Shared Display/Control,

DCS or Remote Control Panel Normally Accessible to Operator

Shared Display/Control,

Local Control Panel Normally Accessible to Operator

Programmable Logic

Control, Field Mounted

Programmable Logic

Control, DCS or Remote

XXXXX

Capillary Tube

Electrical Signal

Internal System Link

(Software or Data Link)

Mechanical Link

LLLLL

Hydraulic Signal

EQUIPMENT TYPE

V100

SERIES NUMBER

Equipment Number

Identiﬁ cation

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1 – 9

1 – 10 / Blank

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 2 • Theory of Operation

1 2 3 4

SUCTION GAS

1/4” OIL CHARGING

BLEED

MOTOR

FILTER

DRAIN

FILTER

DRAIN

OPTIONAL DUAL OIL FILTERS

BLEED

COMPRESSOR

BLEED

STANDARD SINGLE

OIL FILTER

FILTER

BLEED

DRAIN

DISCHARGE

CHECK

STOP VALVE

VALVE

1/4”

OIL SEPARATOR

DRAIN

MOTOR

PUMP

100#

OIL COOLER

VENT

OPTIONAL REMOTE AIR COOLED OIL COOLER

Figure 2-1. Gas Compressor Unit P&ID

The gas and oil systems work in unison, but each one will be explained separately. Reference Figure 3 - Gas Compressor Unit P&ID for gas and oil ﬂ ow descriptions.

Gas Flow

The gas compression process begins as processed gas enters the suction inlet (1). The processed gas ﬂ ows through a stop valve (2), check valve (3) then through a suction line strainer (4) to the compressor (14). The processed gas is then pressurized through the compressor and discharged as high pressure gas vapor into the oil separator (13). In the oil separator, the oil is then separated from the discharged gas vapor by impingement separation. The high pressure gas ﬂ ows out to

OIL DRAIN

STANDARD WATER COOLED OIL COOLER

DRAIN

the aftercooler and scrubber for cooling while the oil is pumped or syphoned back to the compressor.

Moreover, check valves (3) and (6) are provided between the oil separator to prevent gas vapor or liquid from ﬂ ow- ing back to the compressor during shutdown periods.

An equalizing line is also installed between the high pressure side (oil separator) and low pressure side (suc-

tion) to allow .

Oil Life and Oil Flow

The life of the oil is directly affected by the quality of the gas. Proper separation of any liquids must be accomplished to prevent droplets of liquid at the compressor

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2 – 1

Section 2 • Theory of Operation

suction. The discharge temperature of the compressor must be kept a minimum of 30°F (or 17°C) above the discharge gas dew point to prevent the condensing of liquids in the oil separator. The oil separator shell and legs must be insulated when the gas stream has a high probability of having condensables.

Oil in the gas compressor unit serves three primary purposes. They are compressor lubrication, sealing clearances between moving parts, and heat removal resulting from heat of compression and friction. Initially, oil ﬂ ow is driven by a mechanical gear pump (7). Once the system reaches design conditions, the oil pump is shut off and oil ﬂ ow is maintained by differential pressure in the gas system.

As the oil is separated from the gas in the oil separator, it is pumped or syphoned through an oil cooler (9), then ﬁ ltered through a single (11) or dual oil ﬁ lters (15) and back to the injection port of the compressor (14). The standard oil cooler is a shell and tube water cooled heat exchanger (9). The other option is to air cool oil remotely through a ﬁ nned fan heat exchanger (8).

Furthermore, to collect oil from the coalescing side of the oil separator (12), a line is installed between the oil separator and the compressor. By opening the shut-off valve (6), this will allow oil dripping off the coalescing ﬁ l- ters to be fed back to the compressor. In addition, the oil cooler (8 or 9) is piped in parallel to the oil temperature control valve (oil mixing vlave) (10), which acts as a bypass valve.

On units with a full-time oil pump, oil pressure is regulated by the oil pressure regulator (12). It controls upstream pressure to the compressor bearings and should be adjusted to hold the oil pressure at 20 psig above suction pressure. Excess oil not required for bearing lubrication is passed through the regulator and back into the oil separator (13).

This is a continuous cycle.

RTDs and Pressure Transducers

Resistance Thermometers (RTDs) and pressure transducers are instruments used to measure temperatures and pressures at speciﬁ c locations on the gas compressor unit, see Figure 1-2. Gas Compressor Unit Components. RTDs are typically mounted on the suction pipe, discharge pipe, oil separator and oil ﬁ lter outlet pipe. Pressure transducers are typically mounted on the block and bleed assembly and directly on the suction pipe. The pressure transducers measure suction pressure, inlet and outlet oil pressure, and oil separator pressure.

Control System

The gas compressor unit is controlled by a Programmable Logic Controller (PLC) panel. This PLC panel’s main function is to control the gas compression system from the data that it receives from the sensors around the unit. Refer to Compact Logix PLC manual (35391CL) for additional information.

2 – 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Delivery Inspection

All equipment supplied by Vilter are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the units should be thoroughly inspected upon arrival, prior to off-loading. Any damage noted should be photographed and reported immediately to the transportation company. This way, an authorized agent can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilter representative or the home ofﬁ ce should be notiﬁ ed of any claims made within ten (10) days after its discovery. Refer to long term storage for additional recommendations.

Rigging and Lifting of Compressor Unit

WARNING

When rigging and lifting a compressor unit, use proper lifting device capable of lifting and maneuvering the weight and size of the compressor unit. Use only qualiﬁ ed personnel and additional personnel and lifting equipment (i.e. spreader bar) as required. Failure to comply may result in death, serious injury

and/or damage to equipment.

Only qualiﬁ ed personnel shall operate rigging and lift- ing equipment. Ensure that the lifting device is capable of lifting the weight of the compressor unit, refer to the supplied Vilter General Assembly (GA) drawing.

To lift the compressor unit, use lifting points on compressor unit frame to attach the lifting device, see Figure 3-1. There are a few points to consider prior to moving the unit:

• Ensure that the weight is evenly distributed amongst the lifting device (i.e. lifting chains and spreader bar) prior to lifting.

• Ensure that the lifting device is not obstructed by any parts of the compressor unit to prevent damage to components.

• Use additional personnel as needed to spot and aid in maneuvering the compressor unit.

• Ensure there is plenty of space to maneuver the compressor unit and a clear path to its location.

Lifting Point

Use lifting chains/straps and spreader bar. Evenly distribute weight. Keep lifting chains and spreader bar clear of components to prevent damage.

Figure 3-1. Rigging and Lifting Points

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3 – 1

Section 3 • Installation

Long Term Storage Recommendations

The procedure described is a general recommendation for long term storage (over one month of no operation) of Vilter compressor units. It is the responsibility of the installation ﬁ rm and end user to address any unusual conditions. Use the supplied long term storage log sheet to help with record keeping, see section page 3-3.

Warranty of the system remains in effect as described at the beginning of this manual, section page i.

The following are recommendations regarding long term storage:

• If the unit is designed for indoor duty, it must be stored in a heated building.

• If the unit is designed for outdoor duty and is to be stored outdoors, a canvas tarp is recommended for protection until installation. Adequate drainage should be provided. Place wood blocks under the base skid so that water does not collect inside the base perimeter or low spots in the tarp.

• All compressor stop valves are to be closed to isolate the compressor from the remainder of the system. All other valves, except those venting to atmosphere, are to be open. The unit is shipped with dry nitrogen holding charge of approximately 5 psi above atmospheric pressure. It is essential that the nitrogen holding charge be maintained.

• The nitrogen or clean dry gas holding charge in the system and compressor are to be monitored on a regular basis for leakage. If not already installed, it is required that a gauge is to be added to help monitor the nitrogen holding charge pressure. If a drop in pressure occurs, the source of leakage must be found and corrected. The system must be evacuated and recharged with dry nitrogen to maintain the package integrity.

• Cover all bare metal surfaces (coupling, ﬂ ange faces, etc.) with rust inhibitor.

• Desiccant is to be placed in the control panel. If the panel is equipped with a space heater, it is to be energized. Use an approved electrical spray-on corrosion inhibitor for panel components (relays, switches, etc.)

• All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed with desiccant bags inside.

COMPRESSOR MOTOR

The following are general recommendations. Refer to speciﬁ c motor manufacturer instructions for storage recommendations.

• Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the openings. Insert one-half pound bags of silicagel (or other desiccant material) into the air inlets and outlets of drip-proof type motors.

NOTE

Bags must remain visible and tagged, so they will be noticed and removed when the unit is prepared for

service.

• Cover the motor completely to exclude dirt, dust, moisture, and other foreign materials.

• If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent plastic bag. Before sealing this bag, a moisture indicator should be attached to the side of the motor and several bags of silica-gel desiccant be placed inside the bag around the motor. When the moisture indicator shows that the desiccant has lost its effectiveness, replace desiccants.

• Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F above the ambient temperature.

• Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate ﬂ at spots on the bearing surfaces. For motors utilizing anti-friction bearings, the shaft should be rotated once every 30 days by hand at 30 RPM for 15 seconds in each direction. Bearings should also be re-lubricated at 2-year intervals using the grease speciﬁ ed on the motor lubrication nameplate.

• If the compressor unit is installed, wired and charged with oil, open all oil line valves and run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while the compressor shaft is being turned to help lubricate the surfaces of the shaft seal.

For additional storage information, refer to Appendices.

3 – 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

AIR COOLED OIL COOLERS

The following are general recommendations. Refer to speciﬁ c air cooled oil cooler manufacturer instructions for storage recommendations.

• If the coolers are to be stored or not operated for an extended period of time, the fan motors may ingress moisture if they are not protected or operated regularly. In severe cases, the moisture will reduce the insulation level of the windings or cause rusting of the bearings necessitating removal for repairs at a motor repair facility. This is a common problem with large generating installations when the coolers are often ready but commissioning of the main turbine-generator is delayed for several months.

• The simplest remedy for installed coolers is to operate the fan motors for a few hours every week during the downtime period until regular operation resumes. The fan motors on stored coolers must be protected from the elements by covering them with waterproof tarps.

Compressor Unit Inspections Prior to Storage or Installation

The compressor unit must be inspected prior to installation since components could have come loose and/or damaged during shipment or moving.

• Check for loose bolts, particularly the compressor and motor mounting nuts.

• Check for bent or damaged components. The compressor unit should have also been inspected prior to off-loading, see Delivery Inspection.

• Check that the nitrogen pressure is still holding pressure. The pressure gauge is located at the discharge bleed valve on the block and bleed assembly. Any leaks must be ﬁ xed and the system purged and re- charged with dry nitrogen.

Recommended Onsite Tools

The tools recommended to have on site are important for troubleshooting, inspections and compressor unit operation. Besides general mechanic tools, these tools are recommended:

• Oil Pump (maximum of 2-3 GPM with motor approved for Division 1 or Division 2 and with ability to overcome suction pressure)

• Infrared Heat Gun

• Torque Wrenches (with ranges from 0 to 600 ft-lbs)

• Sockets and wrenches up to 2-1/2” (63.5 mm)

• Voltmeter

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3 – 3

Section 3 • Installation

LONG TERM STORAGE LOG

Date: _______________________________

Name: _______________________________ Intial:_______________ Company:

Vilter Order No. _____________________________________________

Compressor Serial Number: ________________________________________________________

Was Compressor Shaft Rotated? _______YES _______ NO HOW OFTEN? __________

Was Air Cooled Oil Cooler Rotated? _______YES _______ NO HOW OFTEN? __________

Was Compressor Motor Rotated? _______YES _______ NO HOW OFTEN? __________

Was Compressor Motor Lubricated? _______YES _______ NO HOW OFTEN? __________

What was the Nitrogen pressure? _______PSIG

Was it necessary to recharge with Nitrogen? ________YES _______NO

If unit needed recharging, was the leak found? ________YES _______NO

Please briefly explain nature of leak:

Is compressor stored in a building that is heated and insulated to prevent condensation of moisture and freezing of Equipment?

___________YES _________NO

Are all machined surfaces exposed to atmosphere coated with a light grease to prevent rusting (compressor shaft)?

__________YES _________NO

Compressor has been placed in operation as of: DATE ______________

3 – 4

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Foundation

Vilter Single Screw compressor units are low vibration machines. Under most conditions, no elaborate foundation is necessary. However a sound foundation maintains motor alignment and proper elevation, and is therefore required. Provided are recommendations for the foundation and anchoring of the compressor unit. The Vilter foundation supports the entire operating weight of the unit and is suitable for years of continuous duty. Included are speciﬁ cations for concrete, rebar, ag- gregate, anchors and grout.

Considerations Prior to Starting

Consult professionals, such as building inspectors, structural engineers, geotechnical engineers and/or construction contractors prior to starting. Below are a few points to consider:

Site Characteristics:

• Soil information

• Site drainage

• Wind data

• Seismic zone

• Ingress and egress

• Power and power lines

Site Layout:

• Plant elevations, grading, drainage and erosion

• Accessibility to compressors for service

• Location of surrounding buildings

• Property lines and roadways

• Power

• Fire safety

Safety:

NOTE

Always check with a safety engineer before proceeding.

• Arranging equipment with adequate access space for safe operation and maintenance

• Wherever possible, arrange equipment to be served by crane. If not feasible, consider other handling methods

• Make all valves and devices safely accessible

• Use special bright primary color schemes to differentiate service lines

• Lightening protection for outdoor installations

• Relief valve venting

Foundation Materials

Materials needed to build the foundation are forms, concrete, sand, rebar, wire, grout, anchor bolts, expansion board and shims. A set of concrete forms will need to be acquired; generally, these can be rented or constructed from dimensional lumber. There should be enough 4,000 psi concrete with one inch aggregate to build the foundation. Also, there should be enough sand to provide a base of compacted sand four inches thick for the foundation to rest on, see Figure 1 - Concrete Pad with Compressor Unit Dimensions - Side View. The rebar required is ASTM 615, grade 60, sizes #4 and #6. Wires will also be needed to tie the rebar together. The recommended grout is Masterﬂ ow 648CP high performance non-shirk grout to provide at least a 1” thick pad under each foot. The recommended anchors are 5/8” Diameter HILTI HAS SS threaded rod for outdoor installations or HAS-E rods for indoor installations. Anchor bolts shall have a ﬁ ve inch projection and 12-3/8” embedment. The required adhesive is HIT-ICE/ HIT/HY 150 anchoring system. There should be enough one inch expansion boards to go around the perimeter of the foundation. Finally there should be enough shim stock and extra anchor bolt nuts to level the compressor unit.

Building the Foundation

Use the Vilter General Arrangement (GA) and foundation drawings to help secure a building permit and foundation construction. The Vilter GA drawing will have the necessary dimensions required to determine the overall foundation size and where to locate the compressor unit on the foundation. It will also show the dimensions required to form up the housekeeping piers that the compressor unit rests on. The Vilter foundation drawing lists the necessary information to construct a suitable foundation. It includes the rebar requirements and locations. It also shows anchor bolt locations, grouting and the concrete speciﬁ cations. Using the Vilter GA drawing, Vilter foundation drawing and the information from site characteristics, site layout and safety studies will provide enough data to allow building the foundation to proceed.

The foundation is to be cast and permanently exposed against the earth. Therefore, if constructing on an existing ﬂ oor, typically indoors, the ﬂ oor will need to be bro- ken up to get to the earth. If starting from undisturbed soil, it must be also be prepared accordingly. In either case, these are some check points to consider:

• Check the depth of your frost line to ensure the foundation extends below it

• Ensure the foundation rests entirely on natural rock or entirely on solid earth, but never on a combination

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 5

Section 3 • Installation

of both

• Check the ability of the soil to carry the load

• Check wet season and dry season soil characteristics for static loading limits and elasticity

• Check local codes for Seismic Design requirements

For examples of foundation diagrams, see to Figure 3-2 and Figure 3-3.

G.A.

trolled level and a surface texture etched in place. Leave the concrete to cure for at least 28 days.

Compressor Unit Installation

Once the foundation has cured, the compressor unit can be placed on the foundation, see Figure 3-5 and Figure 3-6. With the appropriate material handling equipment, lift the compressor unit by locations shown on the Vilter GA drawing and slowly place it on the

G.A.

COMPRESSOR UNIT

CENTER LINE OF GAS COMPRESSION SYSTEM

1'-0"

EL. TOP OF GRADE

3" CLR. 2" CLR.

# 6 @ 12" EACH WAY TOP & BOTTOM

2" (TYP.)

Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View

NOTE

In Figures 3-3 and 3-8, the recommended housekeeping height of 6” is to allow maintenance/

service of the oil strainer and oil pump.

Once the site has been excavated and prepared, place four inches of sand down on the bed where the foundation will rest. The sand must be compacted before placing the forms and rebar. After the sand is compacted, use the Vilter GA drawing to construct the forms for the foundation. With forms in place, install expansion boards on the inside of the forms, for example, see Figure 3-4. Next, place your rebar in the forms as per the Vilter foundation drawing. When all rebars are in place the concrete can be poured. The concrete must then be

4" COMPACTED SAND

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

foundation housekeeping piers. As per the Vilter GA drawing, ensure the compressor unit is correctly placed on the foundation. Once placed, use the spherical washers directly under the compressor as the surface to level the compressor unit, see Figure 3-7. Place shims under the feet of the compressor unit, as needed, until it is leveled, see Figure 3-8. Select the correct drill bit and drill thru the anchor bolt hole in the mounting feet of the compressor unit to the depth called for on the Vilter foundation drawing. Finally using the HILTI instructions, put your anchor bolts in place and wait for them to cure. Then place the nuts on the anchor bolts to ﬁ nger tight and prepare to grout.

3 – 6

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Leveling and Grouting

The unit should be level in all directions. Wet the concrete pad according to the grout manufacturer’s directions. Mix a sufﬁ cient amount of grout. The grout must be an expanding grout rather than shrinking to provide a tighter bond. Follow the manufacturer’s

COMPRESSOR UNIT

EL. TOP OF GRADE

recommendations for setting, precautions, mixing, and grout placement, ﬁ nishing and curing. The grout must be worked under all areas of the feet with no bubbles or voids. If the grout is settled with a slight outside slope, oil and water can run off of the base. Once the grout has cured, torque the anchor bolts as per HILTI instructions.

G.A.

CENTER LINE OF GAS COMPRESSION SYSTEM

# 6 @ 12" EACH WAY TOP & BOTTOM

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL

WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View

ISOLATION JOINT, 1" MINIMUM

COMPRESSOR UNIT

CHAMFER EDGE

THICKNESS

FOUNDATION

6”

CONCRETE SLAB IN BUILDING

Figure 3-4. Interior Foundation Isolation

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3 – 7

Section 3 • Installation

Additional Information

Codes and Standards Vilter followed the following codes and standards when designing your foundation:

• ACI

• ASTM

• ASCE 7

• IBC 2006

Operation and Performance The foundation was designed for:

• Outside environment severe exposure

• Ambient temperature -10 degrees F to 105 degrees F

• Unit weight 20,000 lbs

• RPM 3600

• Soil bearing capacity 1,500 lbs/sq.ft.

• Wind speed 120 MPH

• Exposure factor D

• Wind importance factor 1.15

• Concrete poured on and permanently cast against the earth

General Design Requirements The compressor foundation is designed to:

• Maintain the compressor in alignment and at proper elevation.

• Minimize vibration and prevents its transmission to other structures

• Provide a permanently rigid support

• Provide sufﬁ cient depth to dampen vibrations.

10'-0"

5'-0"

OVER ALL G.A. LENGTH + 4'-0"

CENTER LINE GAS COMPRESSION SYSTEM

3 – 8

Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

1" (TYP.)

G.A.

G.A.G.A.

(2) - # 4 CLOSED TIES

CENTER LINE

G.A. + 2"

G.A.

(5) - # 6 VERT. WITH STD. 90° HOOK

AT BOTTOM EACH

FAC E

5/8" DIA. HILTI HAS SS THREADED ROD (HAS-E RODS ARE ACCEPTABLE FOR INTERIOR INSTALLATIONS) INSTALLED USING HIT-ICE/HIT-HY 150 ADHESIVE ANCHORING

SYSTEM. (5" PROJECTION, 12 3/8" EMBEDMENT.)

HOLES TO BE INSTALLED WITH HAMMER DRILL.

DO NOT DIAMOND CORE.

Figure 3-6. Housekeeping Pad Dimension Detail - Top View

(TYP.)

COMPRESSOR UNIT

LEVEL

HOUSEKEEPING PADS

SPHERICAL WASHERS

Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 9

Section 3 • Installation

70+6.')

010Ä5*4+0-

'21:;)4176

4'%1//'0&'&

(14

*175'-''2+0)

%10%4'6'

$#5'

Figure 3-8. Concrete Pad Housekeeping Detail

Piping

The ideal load applied to ﬂ anges of the compressor unit is zero. However, it’s not practical to expect that no loads will be applied to unit connections. Thermal, dead, live, wind & seismic loads must be considered and even tolerated. Well supported external piping connected to the compressor will still result in some loads applying forces and moments in three axes to unit ﬂ anges.

The most important issue is the motor-compressor misalignment caused by external forces (F in lbf) and moments (M in ft-lbf) imposed by plant piping. In Figure 3-9 and Table 3-2, are the maximum allowable forces and moments that can be applied to compressor ﬂ anges when the compressor is mounted on an oil separator.

It must be noted that it is necessary to check for compressor shaft movement when the job is complete. In no case shall the attached piping be allowed to cause more than 0.002” movement at the compressor shaft. If more than 0.002” movement is detected the piping must be adjusted to reduce the compressor shaft movement to less than 0.002”. For example, the compressor shaft should not move more than 0.002” when piping is removed or connected to the compressor.

IMPORTANT – piping elements shall be supported per the requirements of ASME B31.5 / B31.3 as applicable. See guidelines below, particularly with concern to minimizing loads on check valves.

3 – 10

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

*1.&&190076

9#5*'4

/+0

Header Piping and Drains

Header drains should also be installed to allow drainage of liquids from the discharge and suction headers. See Appendices for Recommended Header Piping.

.'8'.+0)076

#0%*14$1.6

CAUTION

Accumulated liquid in the suction header can damage the compressor if not drained. Always drain headers (suction and discharge headers) prior to start-ups. Failure to comply may result in damage to equipment.

Remote Air Cooled Oil Cooler Piping

If equipped with a remote air cooled oil cooler, it is important that the piping be installed correctly to and from the compressor unit and remote air cooled oil cooler. See Appendices for Recommended Air Cooled Oil Cooler Piping.

Section 3 • Installation

Table 3-2. Maximum Allowable Flange Loads

Nozzle Dia. (in.) Fz (lbf) Fy (lbf) Fx (ft-lbf) Mzz (ft-lbf) Myy (ft-lbf) Mxx (ft-lbf)

4 400 400 400 300 300 300

8 900 900 900 1000 1000 1000

10 1200 1200 1200 1200 1200 1200

12 1500 1500 1500 1500 1500 1500

14 2000 2000 2000 2000 2000 2000

600 600 600 500 500 500

HANGER

CUSTOMER SUPPORTS WHEN CHECK VALVE

IS MOUNTED HERE

5 PIPE DIAMETERS

CUSTOMER SUPPORT

CHECK VALV E

DISCHARGE

LINE

3-4 PIPE DIAMETERS

SUCTION

LINE

CUSTOMER SUPPORT

Figure 3-9. Maximum Allowable Flange Loads

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 11

Section 3 • Installation

General Installation Guideline for

Multiple Air Coolers Installed in a

Common Area

NOTE

This general installation guideline applies to all air coolers on site, whether if they are supplied by or

not supplied by Vilter.

The purpose of this guideline is providing design information when multiple air cooled heat exchangers are installed in a common area. There are two main focal points of this guideline. One area is free ﬂ ow area which addresses how much free area is required to prevent air ﬂ ow “starvation” of the units. The second item provides a guideline as to how multiple air cooled heat exchangers should be arranged to minimize the potential of hot air recirculation due to the environment.

FREE FLOW

There are two basic guidelines that we follow to address free ﬂ ow area when multiple designs are being installed in a common area.

• Air coolers should be placed at least 1 fan diameter away from the nearest obstruction. This is based on the largest fan diameter in the bay of coolers.

• Intake area to the air cooler should have an intake velocity equal to or below 500FPM as the as the discharge velocity is above 500FPM.

We will look at each rule and provide pictorials and

calculations for each guideline. Let’s assume the following coolers are being installed in a common area:

• Cooler 1 - 7’ wide x 10’ long with a 6’ fan moving 55,000CFM of air. Face velocity is 785FPM.

• Cooler 2- 8’ wide x 12’ long with a 7’ fan moving 72,000CFM of air. Face velocity is 750FPM.

• Cooler 3- 10’ wide x 16’ long with a 9’ fan moving 120,000CFM of air. Face velocity is 750FPM.

ONE FAN DIAMETER

In order to keep the leg height of the installation to a minimum we want to install the coolers at least 1 fan diameter from the nearest obstruction. Referring to Figure 3-10, the nearest obstruction is the building.

Based on the information above, the largest fan diameter in the installation is 9ft. Therefore, the coolers should be placed at least 9’ away from the building.

INTAKE VELOCITY

Based on the information above, we are going to solve for the leg height that will provide an intake velocity of 500FPM. We know the following:

• The total airﬂ ow of the installation is 247,000CFM

• We have an intake perimeter of 82’ for all 4 sides based on the cooler placement.

• Our intake velocity guideline is 500FPM

3 – 12

PREFERRED

TOTAL INTAKE PERIMETER = 82 FEET

Figure 3-10. Installation of Coolers - One Fan Diameter Next to Building

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Intake Velocity

Less

Figure 3-11. Leg Height

The equation used to calculate the leg height in Figure 3-11 is as follows:

Leg Height = (Total Airﬂ ow/Intake velocity)/Intake Perimeter

Leg Height = (247,000CFM/500FPM)/82ft

Leg Height = 6ft

In this particular case the calculated minimum height is 6 feet to maintain an intake velocity of 500FPM or less based on having the coolers place 1 fan diameter away from the nearest obstruction. Let’s look at an installation where the coolers need to be placed next to the building as in Figure 3-12.

Based on the information above, we are going to solve for the leg height that will provide an intake velocity of 500FPM. We know the following:

NOT PREFERRED

• The total airﬂ ow of the installation is 247,000CFM

• We have an intake perimeter of 3 sides 16ft, 16ft, and 25ft which totals 57’

• Our intake velocity guideline is 500FPM

The equation used to calculate the leg height in Figure 3-11 is as follows:

Leg Height = (Total Airﬂ ow/Intake velocity)/Intake Perimeter

Leg Height = (247,000CFM/500FPM)/57ft

Leg Height = 8.667ft

We would round the leg height up to 9ft for this particular situation.

TOTAL INTAKE PERIMETER = 57 FEET

Figure 3-12. Installation of Coolers - Next to Buildling

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 13

Section 3 • Installation

HOT AIR RECIRCULATION

There are two situations where hot recirculation could occur.

• Intake velocity of the cooler is higher than the discharge velocity

• Environmental issues such as strong cross winds which is installation speciﬁ c

We addressed how to minimize the opportunity for hot air recirculation involving the operation of the air coolers under the guidelines for the Free Flow section above. However, environmental hot air recirculation is something that is outside of the control of the cooler manufacturer. If the site has the potential for strong cross winds or tunneling then you may want to consider the following items to minimize the potential of hot air recirculation due to the environment.

• All air coolers should discharge at the same elevation.

• If feasible all of the air coolers in a common area should be placed as close to the next cooler as possible.

This is especially critical if all of the air coolers are not place as close together as possible.

Cooler Placement and Spacing

The concern about cooler placement as far as proximity from one another has to do with the potential for hot air recirculation due to cross winds. Let’s look at only having coolers 1 and 3 in the same area. The leg height requirement of cooler 1 is 3.23ft so we would use a 4ft leg height. The leg height requirement for cooler 3 is

4.61ft but we would put a 7 foot leg height on the cooler due to size and for serviceability. Figure F. shows this installation.

In this case, if you get a strong cross wind from left to right there is the potential that the discharge coming from the top of cooler 1 could easily be pushed into the intake of cooler 3. Thus, in Figure 3-14, the not preferred conﬁ guration is more susceptible to the potential of hot air recirculation due to the environment and is not recommended. The preferred conﬁ guration is the recom- mended installation of the coolers with a space between them.

Unfortunately this comes with a cost. By reducing the intake perimeter available, the leg height increases, which is a cost. In addition there is no guarantee that hot air recirculation can be eliminated due to environmental issues.

Discharge Elevation

In order to minimize the potential for hot air recirculation, it is recommended to install the air coolers so that they all discharge at the same elevation. This is important because not all air coolers have the same plenum heights. You can satisfy the leg height requirements by the calculation above but not satisfy the requirements for discharge elevation. Based on the size of the coolers above, cooler 1 has a plenum height of 36”, cooler 2 has a plenum height of 42”, and cooler 3 has a plenum height of 54”. Plenum heights are calculated from the standard of a 45 degree dispersion angle in API 661. If you would like more details on this calculation please contact engineering.

As you can see in Figure 3-13 in the not preferred conﬁ guration. the leg height requirement in the ﬁ rst cal- culation is satisﬁ ed. However, the coolers are not at the same discharge elevation. This could be an issue if there is a cross wind from left to right. Cooler 3 could block the discharge air ﬂ ow from coolers 1 and 2 and recirculate it back down to the intake of the coolers. The best way to address this is to increase the leg heights on coolers 1 and 2 as shown in the preferred conﬁ guration.

All of the information provided is a general guideline for installing multiple air coolers in a common area. If you minimally follow all of the Free Flow requirements and keep the air coolers discharging at the same elevation then you have a good basis for site layout.

Sometimes due to extenuating circumstances, the above guidelines cannot be followed. Please contact engineering to discuss remedies to accommodate different conﬁ gurations.

3 – 14

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

NOT PREFERRED PREFERRED

Figure 3-13. Discharge Elevation of Coolers

NOT PREFERRED

PREFERRED

Figure 3-14. Cooler Placement and Spacing

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 15

Section 3 • Installation

Pressure Testing

CAUTION

Do not hydro test compressur unit. Failure to comply

may result in damage to equipment.

CAUTION

The compressor unit along with other system units contain many components with various pressure ratings. Pressure relief protection provided considers the design pressure of a system components. Before replacing a pressure relief valve with a relie valve having a higher presure setting, all system

components must be evaluated for acceptability.

Pressure test in compliance with Chapter VI of the ASME B31.3 Process Piping Code.

Initial Oil Charging

Using Non -Vilter Oils

CAUTION

Do not mix oils. Failure to comply may result in

damage to equipment.

NOTICE

Vilter does not approve non-Vilter oils for use with Vilter compressors. Use of oils not speciﬁ ed or

supplied by Vilter will void the compressor warranty.

Due to the need for adequate lubrication, Vilter recommends only the use of Vilter lubricants, designed speciﬁ cally for Vilter compressors. With extensive research that has been performed, we are able to offer gas compression lubricating oils. Use of oil not speciﬁ ed or sup- plied by Vilter will void the compressor warranty.

Please contact your local Vilter representative or the Home Ofﬁ ce for further information.

Unit Oil Charging and Priming

WARNING

Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply

may result in serious injury or death.

NOTICE

Failure to follow these instructions will result in bearing damage and compressor seizing and will void

any and all warranties that may apply.

Typically, the compressor unit is shipped from Vilter with no oil charge. The normal operating level is between the two sight glasses on the oil separator, see Figure 3-15. Refer to supplied GA drawing for unit speciﬁ c oil charge requirement.

For regular oil charging and draining procedures, see Section 5.

Tool Required:

• Oil Pump, Maximum 2-3 GPM with Motor approved for Division 1 or Division 2 and with ability to overcome suction pressure.

(Reference Figure 3-17)

1. At initial start up, compressor unit must be off and

depressurized prior to initial oil charging.

2. Using a properly selected oil pump, connect oil

pump to oil separator drain valve (4). For oil separator drain valve location, see Figure 3-16.

3. Open oil separator drain valve (4) and ﬁ ll oil separa-

tor (3) to Maximum NON-Operating Level.

4. Once Maximum NON-Operating Level has been

reached, shut off oil pump, close oil separator drain valve (4) and remove oil pump.

5. If equipped with remote oil cooler, refer to Priming

Remote Oil Cooler and Piping procedure.

PRIMING OIL COOLER (SHELL AND TUBE) AND PIPING

If equipped with a shell and tube oil cooler, continue with the following steps:

6. Close shut-off valve (8) at oil ﬁ lter inlet. Do the same

for second oil ﬁ lter, if equipped with dual oil ﬁ lters. For shut-off valve location, see Figure 3-16.

7. Open oil bypass shut-off valve (5). For oil cooler by-

pass valve location, see Figure 3-16.

8. Energize compressor unit.

9. Close oil mixing valve (oil temp. control valve) (7) via

control panel. In Manual Mode, change “Manually Open (%)” value to “0”.

NOTE

The oil cooler is considered primed when the oil

level in the separator is constant.

10. Run the oil pump (6) twice for 1-2 minutes. Repeat

this step until the oil level (9) is constant.

3 – 16

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

Normal Operating Level

Maximum NON-Operating Level

View Rotate 180°

Oil Filter Shut-Off Valves

Figure 3-15. Oil Operating Levels

Suction Oil Charging Valve

Minimum Operating Level

Oil Drain Valve (Oil Separator)

Bypass Valve (Oil Cooler)

View From Back - View Rotate 180°

Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 17

Section 3 • Installation

PRIMING COMPRESSOR AND OIL FILTERS

NOTE

Running the compressor oil pump at this point will help lubricate the compressor bearings and shaft

seal surfaces.

(Reference Figure 3-19)

11. Open shut-off valve(s) (8) at oil ﬁ lter inlet(s).

12. Close oil bypass shut-off valve (5).

13. Open oil mixing valve (7) via control panel. In Manual Mode, change “Manually Open (%)” value to “100”.

14. Run oil pump (6) for approximately 20 seconds only.

15. Stop oil pump (6) and wait for a minimum of 30 minutes. This will allow oil in the compressor (2) to drain and oil level (9) in separator (2) to settle.

SUCTION INLET

OIL CHARGE

PT 001

BLEED

PRESSURE

MOTOR

EQUALIZING LINE

NOTE

Oil mixing valve can remain in Manual Mode since the setpoint will change the mode to Auto when reached. For further details, see PLC Compact Logix

manual.

16. Refer to Pre Start-Up Checklist and ensure all items are ready prior to starting the compressor.

17. When ready, run compressor unit and allow it to reach normal operating temperature.

18. Using a properly selected oil pump, connect oil pump to suction oil charging valve (1). For suction oil charging valve location, see Figure 3-16.

19. Open suction oil charging valve (1) and ﬁ ll oil separa- tor (3) to Normal Operating Level.

20. Once the Normal Operating level has been reached, shut off the oil pump and close the suction oil charging valve (1). Disconnect and remove oil pump.

DISCHARGE OUTLET

002

001

004

RETURN

SUPPLY

COOLING WATER

DRAINVENT

COMPRESSOR

001

COALESCING OIL RETURN LINE

OIL FILTER

Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping

002

BLEED

001

OIL

1000W 1000W 1000W

101

005

OIL MIXING

OIL SEPARATOR

002

102

103

VALVE

PT 004

BLEED

OIL COOLER

DRAIN

MOTOR

OIL PUMP

DRAIN

OPEN

DRAIN

3 – 18

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

NOTE

Oil separator does not need to be ﬁ lled again until oil

level reaches Minimum Operating Level.

Every size of compressor will hold different amounts of oil, so amount of oil draining back into oil

separator will vary.

21. More accurate ﬁ ll levels can be accomplished by marking the level on the oil separator (2) after correct levels have been achieved during the unit operation and when the compressor unit has been down for 1 hour.

SUCTION INLET

OIL CHARGE

PT 001

BLEED

PRESSURE

EQUALIZING LINE

MOTOR

DISCHARGE OUTLET

002

TE 001

004

RETURN

SUPPLY

COOLING WATER

DRAINVENT

COMPRESSOR

OIL COOLER

DRAIN

MOTOR

OIL PUMP

FG 001

COALESCING OIL RETURN LINE

OIL FILTER

PT 002

BLEED

002

102

OPEN

OIL SEPARATOR

103

001

OIL

1000W 1000W 1000W

101

005

OPEN

OIL MIXING

VALVE

OPEN

004

BLEED

Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping

DRAIN

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 19

Section 3 • Installation

Priming Remote Oil Cooler and Piping

(Initial Oil Charging)

WARNING

Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply

may result in serious injury or death.

NOTICE

Failure to follow these instructions will result in bearing damage and compressor seizing and will void

any and all warranties that may apply.

NOTE

This procedure is for remote oil coolers only.

Piping of oil must enter bottom connection of remote oil cooler and leave from top connection. For remote air cooled oil cooler piping, see Piping

section.

SUCTION INLET

PT 001

BLEED

OIL CHARGE

001

(Reference Figure 3-19)

1. Verify oil level (8) is at Maximum Non-Operating Oil Level in separator (3). If oil level is not at Maximum Non-Operating Oil Level, add oil, see Initial Oil Charging - Unit Oil Charging procedure.

2. Close shut-off valve(s) (7) at oil ﬁ lter inlet(s).

3. Open oil bypass shut-off valve (4).

4. Energize compressor unit.

5. Close oil mixing valve (oil temp. control valve) (6) via control panel. In Manual Mode, change “Manually Open (%)” value to “0”.

NOTE

The oil cooler is considered primed when the oil

level in the separator is constant.

6. Run oil pump (5) for a minimum of 5 minutes and as long as needed to purge all gas from oil cooler and piping.

7. When all gas is purged, stop oil pump.

DISCHARGE OUTLET

002

004

REMOTE

OIL COOLER

PRESSURE

EQUALIZING LINE

001

COALESCING OIL RETURN LINE

OIL FILTER

MOTOR

COMPRESSOR

007

VENT

002

BLEED

001

OIL

1000W 1000W 1000W

101

005

OIL MIXING

OIL SEPARATOR

002

102

VALVE

PT 004

BLEED

DRAIN

103

OPEN

MOTOR

OIL PUMP

007

DRAIN

003

3 – 20

Figure 3-19. Priming Remote Oil Cooler and Piping

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

PRIMING COMPRESSOR AND OIL FILTERS

NOTE

Running the compressor oil pump at this point will help lubricate the compressor bearings and shaft

seal surfaces.

(Reference Figure 3-20)

8. Open shut-off valve(s) (7) at oil ﬁ lter inlet(s).

9. Close oil bypass shut-off valve (4).

10. Open oil mixing valve (6) via control panel. In Manual Mode, change “Manually Open (%)” value to “100”.

11. Run oil pump (5) for approximately 20 seconds only.

12. Stop oil pump and wait for a minimum of 30 minutes. This will allow oil in the compressor (2) to drain and oil level (8) in separator (3) to settle.

NOTE

Oil mixing valve can remain in Manual Mode since the setpoint will change it to Auto mode. For further

details, see PLC Compact Logix manual.

13. Refer to Pre Start-Up Checklist and ensure all items are ready prior to starting the compressor.

SUCTION INLET

001

OIL CHARGE

BLEED

14. When ready, run compressor unit and allow it to reach normal operating temperature.

15. Using a properly selected oil pump, connect oil pump to suction oil charging valve (1). For suction oil charging valve location, see Figure 3-16.

16. Open suction oil charging valve (1) and ﬁ ll oil separa- tor (3) to Normal Operating Level.

17. Once the Normal Operating level has been reached, shut off the oil pump and close the suction oil charging valve (1). Disconnect and remove oil pump.

NOTE

Oil separator does not need to be ﬁ lled again until oil

level reaches Minimum Operating Level.

Every size of compressor will hold different amounts of oil, so amount of oil draining back into oil

separator will vary.

18. More accurate ﬁ ll levels can be accomplished by marking the level on the oil separator (2) after correct levels have been achieved during the unit operation and when the compressor unit has been down for 1 hour.

002

001

004

DISCHARGE OUTLET

REMOTE

OIL COOLER

PRESSURE

EQUALIZING LINE

001

COALESCING OIL RETURN LINE

OIL FILTER

MOTOR

COMPRESSOR

002

BLEED

001

OIL

1000W 1000W 1000W

101

005

OPEN

OIL MIXING

OPEN

OIL SEPARATOR

002

102

OPEN

VALVE

004

BLEED

DRAIN

103

OIL PUMP

Figure 3-20. Priming Compressor and Oil Filters

MOTOR

007

DRAIN

VENT

DRAIN

003

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 21

Section 3 • Installation

Pre Start-Up

The following check list is to help prepare the equipment before the Vilter technician arrives at the jobsite. Vilter recommends that a trained technician go through the following tasks. The operating manuals provided by Vilter can be referenced for any type of questions or special instructions.

Every gas compressor unit includes a Vilter start-up (confirm on P.O.). The following tasks are not included in the Vilter start-up provided in your equipment purchase. Any tasks below that are done by the Vilter technician will take away from the pre-determined time that was provided with the equipment purchase. Vilter suggests that the Vilter technician’s time be used during the start-up of the system and not for the below system preparation.

NOTICE

Each item below must be checked-off, signed and returned to Vilter Service Department. Failure to do

so will “Null & Void” future warranty considerations.

Pre Start-Up Checklist

Name (Please Print): Signature:

Company: Vilter Sales Order Number:

Equipment Description: Date (M/D/Y):

1. The unit should be leveled and secured to the concrete pad foundation.

2. Proper electric supply and grounding need to be supplied to the unit. All power and control lines should be wired to unit. Electric supply to be veriﬁ ed at each device requiring power.

3. Verify any type of level switches that are on a vessel before the compressor are hardwired and able to shut off the compressor (should be wired to “Aux” on micro-controller and starter).

4. The suction and discharge line must be piped and properly supported independent of the unit.

5. The discharge stop and check valve is shipped loose and must be installed. During off periods, liquid can condense in the line downstream of the discharge stop and check valve. It is recommended that the stop and check valve be located horizontally to minimize the quantity of liquid that can accumulate downstream of the check valve.

6. A dual safety relief valve is shipped loose for ﬁ eld installation. A connection is provided on the oil separator for the relief valve. Refer to ASME Code for proper sizing of relief valves and vent lines.

7. On water cooled oil coolers, the water lines must be connected to the front head of the oil cooler. Water regulating and solenoid valves are recommended.

3 – 22

(Continued on next page)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 3 • Installation

8. On air cooled oil coolers, the oil lines from the compressor must be connected to the air cooled oil cooler. Oil cooler fans will need to be wired and checked for proper rotation. Refer to supplied GA drawing for connection points and piping sizes.

9. The oil separator should be charged with oil to the Maximum NON-Operating Level.

10. The center member of the compressor is shipped loose to help facilitate ﬁ nal ﬁ eld alignment and allow for motor rotation check.

11. Both the compressor and motor hubs should be checked for concentricity and perpendicularity.

12. The motor should be checked and shimmed for a soft foot prior to attempting ﬁ nal alignment.

13. The motor should be checked to make sure that it is lubricated properly. Proper re-lubrication amounts/ types are provided on the motor’s lubrication plate. These instructions should be closely followed to achieve optimum bearing life and to avoid consequential damage to the bearings and motor.

14. The center section of the coupling should be left out to allow the start-up technician to verify the ﬁ nal alignment and motor rotations.

15. Verify that all valves are in the open position.

16. Verﬁ y that the visual indicator on the Oil Temperature Control Valve (Oil Mixing Valve) position corresponds with “% OPEN” on the control panel. CLOSE position is 0% OPEN, OPEN position is 100% OPEN.

17. A system load should be available at the time of start-up.

18. The unit should be pressure tested and purged with a dry gas. Care should be taken to not pressurize excessively from the suction end of the compressor, as this will drive the compressor in a forward motion without lubrication and may cause damage.

19. Have a qualiﬁ ed electrician present to verify wiring during start-up.

20. Keep a hard copy of the ﬁ nal set points in case the micro-controller gets corrupted or if they are required by Vilter technicians for troubleshooting.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

3 – 23

Section 3 • Installation

Start-Up

The following check list is to help verify and check equipment prior to start-up. This is the responsibility of the Vilter Technician.

1. Review pre start-up checklist.

2. Check oil pump rotation. This can be done by using the “Diagnostic Force Outputs” from Main Menu. Refer to Compact Logix PLC Software Manual.

3. Check compressor motor rotation (CCW or CW rotation facing compressor shaft). This can be done by using the “Diagnostic Force Outputs” from Main Menu. Refer to Compact Logix PLC Software Manual.

4. Cold and hot alignment. Verify with manufacturer’s limits.

5. Verify capacity slide calibration and correct command shaft rotation, even though it is factory calibrated.

6. Verify volume slide calibration and correct command shaft rotation, even though it is factory calibrated.

7. Check motorized oil mixing valve for proper setup.

8. Starter set up by vendor technician.

9. Blower set up by vendor technician.

10. Verify correct direction of ﬂ ow for the oil line check valve.

11. Run oil pump to pre-lube the compressor (oil level in the oil separator should drop as lines are ﬁ lled).

12. Calibrate transducers to atmosphere.

13. Verify operation of all safeties.

14. Set scaling for main motor amps in PLC.

15. Record running data and ﬁ nal set points on data sheets.

16. Instruct Operators.

3 – 24

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Operation

All operation (setpoint adjustments, calibrations, monitoring) of the compressor unit is done through the Compact Logix PLC. For additional procedural information, refer to Compact Logix PLC Software Manual (35391CL).

Oil Inspection

WARNING

When working with LFG, NG or other dangerous or ﬂ ammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national ﬁ re and building codes. Failure to comply may result in

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in

serious injury or death.

separator, see Figure 4-1. Oil Operating Levels. Drain or

ll oil as required. For oil draining and ﬁ lling procedure,

ﬁ see Oil Charging and Oil Draining in Section 5.Oil Flow with Dual Oil Filters

Dual Oil Filters

On compressor units equipped with dual oil ﬁ lters, only one ﬁ lter should be in operation at a time.

NOTE

During operation, both oil ﬁ lter outlet shut-off valves

should be open. This will help minimize the sudden loss

of oil pressure when switching between oil ﬁ lters for

servicing.

Refer to Oil Filter Replacement in Section 5 for further details.

Inspect oil level through sight glasses on the oil

Normal Operating Level

Maximum NON-Operating Level

Minimum Operating Level

Figure 4-1. Oil Operating Levels

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

4 – 1

Section 4 • Operation

Control System Calibration

Equipped for automatic operation, the screw compressor unit has safety controls to protect it from irregular operating conditions, an automatic starting and stopping sequence, capacity and volume ratio control systems.

Check all pressure controls with a remote pressure source, to assure that all safety and operating control limits operate at the point indicated on the microprocessor.

The unit is equipped with block and bleed valves that are used to recalibrate the pressure transducers. To use the block and bleed valves to recalibrate the pressure transducers, the block valve is shut off at the unit and the pressure is allowed to bleed off by opening the bleed valve near the pressure transducer enclosure. The transducer can then be calibrated at atmospheric pressure (0 psig), or an external pressure source with an accurate gauge may be attached at the bleed valve.

The discharge pressure transducer cannot be isolated from its pressure source, so it is equipped with only a valve to allow an accurate pressure gauge to be attached and the pressure transducer calibrated at unit pressure.

Recheck the transducers periodically for any drift of calibration, refer to maintenance/service interval table in Section 5.

Stopping/Restarting

Stopping the compressor unit can be accomplished a number of ways. Any of the safety setpoints will stop the compressor unit if an abnormal operating condition exists. The compressor unit “On-Off” or stop button will turn the compressor unit off as will the low pressure setpoint. If any of these conditions turns the compressor unit off, the slide valve motors will immediately energize to drive the slide valves back to 5% limit. The control motors will be de-energized when the respective slide valve moves back below 5%. If there is a power failure, the compressor unit will stop. If the manual start on power failure option is selected (see appropriate Microprocessor Instruction Manual), restarting from this condition is accomplished by pushing the reset button to insure positive operator control. If the auto start on power failure option is selected (see Compact Logix PLC manual), the compressor unit will start up after a waiting period. With both options, the compressor slide valves must return below their respective 5% limits

before the compressor unit can be restarted.

NOTE

Wait a minimum of 20 minutes (to allow the compressor unit to equalize to suction pressure) between pre-lubing or pushing the start button.

Starting, Stopping and Restarting the

Compressor

Starting

Before the screw compressor unit can start, certain conditions must be met. All of the safety setpoints must be in a normal condition, and the suction pressure must be above the low suction pressure setpoint to ensure a load is present. When the “ON/OFF” switch or “ManualAuto” button is pressed, the oil pump will start. When sufﬁ cient oil pressure has built up and the compressor capacity control and volume ratio slide valves are at or below 10%, the compressor unit will start.

NOTE

The amount of oil pressure that needs to be achieved

before compressor start is at least 6 psig above the

discharge pressure. For additional information on

Low Oil Pressure at Start, see Troubleshooting Guide -

General Problems and Solutions in Section 6.

If the compressor is in the automatic mode, it will now load and unload and vary the volume ratio in response to the system demands.

Calibrate Slide Valve Actuators

Slide valve actuators must be installed prior to calibration. Refer to Slide Valve Actuator Installation procedure. The following steps pertain to calibrating one slide valve actuator. Repeat procedure to calibrate other slide valve actuator.

WARNING

After stopping the compressor, allow the compressor and surrounding components to cool down prior to servicing. Failure to comply may result in serious

injury.

CAUTION

Do not calibrate in direct sunlight. Failure to comply

may result in damage to equipment.

Both the capacity and volume slide actuators should be calibrated when one or more of these have occurred:

• Compressor unit starting up for the ﬁ rst time.

• A new actuator motor has been installed.

4 – 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Actuator

Assembly

Actuator

Plastic Cover

View Rotate 180°

Red LED

Blue

Calibrate

Button

Figure 4-2. Actuator Assembly

• There is an error code ﬂ ashing on the actuator’s circuit board - an attempt to recalibrate should be made.

• The range of travel is not correct and the command shaft travel is physically correct.

• The compressor is pulling high amperage, the calibration of the volume slide should be checked.

• An actuator does not unload below 5%, or an actuator that doesn’t move.

• Something is not working properly such as the actuators, RTDs or transducers.

To calibrate optical actuators, continue with the following steps:

1. Stop compressor unit and allow to cool.

2. Remove screws securing actuator cover to actuator

assembly. As a reference see Figure 4-2.

CAUTION

Wires are attached to the connector on the actuator cover. Handle actuator cover with care to prevent damage to wires. Failure to comply may result in

damage to equipment.

3. Carefully lift actuator cover from actuator assembly

and tilt towards Turck connectors. Raise cover high enough to be able to press the blue calibration button and be able to see the red LED on the top of assembly.

4. On the main screen of the PLC, press “Menu” then press the “Slide Calibration” button to enter the slide calibration screen, see Figure 4-3.

5. Logging on with high-level access will prompt the Calibrate button to appear, see Figure 4-4.

6. Press Calibrate button to initiate calibration mode. The Calibrate button turns green and Set Max and Set Min buttons appear.

NOTE

If the INC (increase) and DEC (decrease) buttons do not correspond to increase or decrease shaft rotation, swap

the blue and brown wires of the “power cable”. This will

reverse the rotation of the actuator/command shaft.

7. Press INC and DEC to move the slide valve and check for the correct rotation, see Table 4-1.

NOTE

When the actuator is in calibration mode, it outputs

0V when the actuator is running and 5V when it is

still. Thus, as stated earlier, the actuator voltage will

ﬂ uctuate during calibration. After the actuator has been

calibrated, 0V output will correspond to the minimum

position and 5V to the maximum position.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

4 – 3

Section 4 • Operation

4 – 4

Figure 4-3. Menu Screen and Slide Calibration Button (Compact Logix PLC)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Figure 4-4. Slide Valve Calibration Screen (Compact Logix PLC)

8. Quickly press and release the blue push button on the actuator one time. This places the actuator in calibration mode. The red LED will begin ﬂ ashing rapidly.

Press down on Photo-chopper

CAUTION

DO NOT CONTINUE TO ENERGIZE THE ACTUATO MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP. Doing so may cause mechanical damage to the motor or shear the motor shaft key. When the slide has reached the mechanical stop position, press the button in the center of the photochopper to release the brake, and thereby

release the tension on the actuator motor.

NOTE

The “Slide calibration” screen on the Control Panel has a “Current” window, which displays twice the actuator

output voltage. This value, (the % volume and the % capacity) displayed in the “Current Vol” and Current Cap” Windows are meaningless until calibration has

been completed.

9. Use the DEC button on the Control panel to drive the slide valve to its minimum “mechanical stop” position. Do not continue to run the actuator in this direction after the slide valve has reached the stop. Doing so may cause damage to the actuator or the slide valve. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount, see Figure 4-5. Use the INC button

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

10. Quickly press and release the blue button on the ac-

Figure 4-5. Photo-chopper

to pulse the actuator to where the slide is just off of the mechanical stop and there is no tension on the motor shaft.

tuator again. The red LED will now ﬂ ash at a slower rate, indication that the minimum slide valve position (zero position) has been set.

4 – 5

Section 4 • Operation

Table 4-1. Command Shaft Rotation Speciﬁ cations*

Command Shaft Rotation No. of Turns/Rotation Angle/Slide Travel

Capacity Volume Capacity Volume

Compressor

Model

INC DEC INC DEC Turns Degrees Travel Turns Degrees Travel

VSSG 291

SG 341

VSSG 451

VSSG 601

VSG 301

VSG361

VSG 401

VSG 501

VSG 601

VSG 701

VSG 751

VSG 901

VSG 791

VSG 891

VSG 1051

VSG 1201

VSG 1301

VSG 1551

VSG 1851

VSG 2101

VSG 2401

VSG 2601

VSG 2801

VSG 3001

CW CCW CW CCW 0.91 328 3.568” 0.52 187 2.045”

CW CCW CW CCW 0.80 288 3.141” 0.45 162 1.767”

CCW CW CCW CW 0.91 328 3.568” 0.52 187 2.045”

CCW CW CCW CW 1.09 392 4.283” 0.63 227 2.473”

CCW CW CCW CW 1.22 439 4.777” 0.74 266 2.889”

CCW CW CCW CW 1.48 533 5.823” 0.87 313 3.433”

CCW CW CCW CW 1.80 648 7.072” 1.36 490 5.341”

*The large gear on the command shaft has 50 teeth. The teeth are counted when moving the command shaft from the minimum stop position to the maximum stop position.

The manual operating shaft on the gear motor should be turned the opposite direction of the desired command shaft rotation.

The capacity and volume control motors are equipped with a brake, if it is necessary to operate the control motors manually, the brake must be disengaged. The brake can be disengaged by pushing on the motor shaft on the cone end. The shaft should be centered in its travel. Do not use excessive force manually operating the motor or damage may result.

4 – 6

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

11. Use the INC button on the Control panel to drive the slide to its maximum “mechanical stop” position. Do not continue to run the actuator in this direction after the slide valve has reached the stop. Doing so may cause damage to the actuator or the slide valve. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount. Use the DEC button to pulse the actuator to where the slide is just off of its mechanical stop and there is no tension on the motor shaft.

12. Quickly press and release the blue button on the actuator one more time. The red LED will stop ﬂ ashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls. Now the capacity or volume channel of the PLC can be calibrated.

13. Use the DEC button to move the actuator towards its minimum position while watching the mV readout on the Control Panel screen. Discontinue pressing the DEC button when the mV reading the “Current” window above the “Set Min” button is approximately 500 mV.

14. Now use the DEC and INC buttons to position the slide valve until a value close to 300 mV is on the screen. Then, press the “Set Min” button in the capacity or volume slide valve window to tell the controller that this is the minimum mV position. Note: The value in the “Current Cap” or “Current Vol” window has no meaning right now.

15. Use the INC button to rotate the actuator towards its maximum position while watching the mV readout on the controller screen. Discontinue pressing the INC button when the mV reading in the “Current” window is approximately 4800 mV. You are nearing the mechanical stop position.

16. Pulse the INC button to carefully move the slide valve until the mV readout “saturates”, or stops increasing. This is around 4800 mV Record mV maximum reading.

17. Pulse the DEC button until the mV just start to decrease. (This is the point where the channel drops out of saturation). Adjust mV value to 300 mV below recorded maximum mV.

18. Press the “Set Max” button.

19. Press the “Main” button to complete calibration and exit the “Slide Calibration” screen. The controller will automatically energize the actuator and drive it back to its minimum position (below 5%) for pre-start-up.

NOTE

Now the “Current Cap” or the “Current Vol” value will be displayed in the window on the “Main” screen and

the “Slide Calibration” screen.

20. Gently lower the plastic cover over the top of the actuator to where it contacts the base and O-ring seal. After making sure the cover is seated properly, gently tighten the four #10 screws. Caution: The plastic cover will crack if the screws are over tightened.

21. Enable the “Slide Non-Movement Alarm” by going to the “Setup” menu and choosing “Alarm Enable” for the “Slide Non-Movement Option”.

22. Repeat procedure to calibrate other slide valve actuator.

Oil Temperature Control Valve (Oil Mixing Valve) Operation

Initial Position

The temperature control valve is in the closed position when initially installed.

With the temperature control valve de-energized, the valve is set to its initial position. The temperature control valve will be in the closed position with the actuator indicator displaying CLOSED.

When the temperature control valve is energized, the valve will rotate to fully OPEN.

Operation

With the compressor not running, when electrically energized, the PLC will turn the temperature control valve to fully open (100%).

When the compressor starts, the valve remains fully open (100%) until the oil injection temperature rises above the control setpoint. When the oil injection temperature rises above the control setpoint, the oil temperature control valve will begin to close. The hot oil from the oil separator begins to divert to the oil cooler, mixing the hot and cooled oil ﬂ ow streams together down- stream of the oil temperature control valve. The valve can fully close (0%) diverting the entire oil ﬂ ow stream to the oil cooler.

As the oil injection temperature drops below the setpoint, the oil temperature control valve begins to open so that the oil injection temperature does not become too cold.

When the compressor stops, the valve returns to fully open (100%).

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

4 – 7

Section 4 • Operation

Fail Position

The temperature control valve remains in the last position when power is removed.

Screen Display

The oil temperature control valve, identiﬁ ed as “OIL MIX” on the main PLC display screen, shows a numerical value with “%” as units. This is to be understood as “% OPEN.” It is a direct indication of the position of the ball valve.

100% OPEN

Oil ﬂ ow stream is entirely bypassing the oil cooler.

99% to 1% OPEN

Oil ﬂ ow stream is partially bypassing the oil cooler and partially diverted to the oil cooler.

0% OPEN

Oil ﬂ ow stream is entirely diverted to the oil cooler.

MANUAL OVERRIDE

The actuator of the oil temperature control valve has a handwheel that can be engaged to override the electrically determined position of the ball valve.

1. Push handwheel down and rotate to engage internal slot with ﬂ ats, see Figure 4-6.

NOTE

Actuator does not have mechanical stops. Do Not

rotate past open or close position. Use visual indicator

to position actuator.

2. Once engaged, push down handwheel a second time to disengage gear train and rotate CLOCKWISE to OPEN or COUNTER CLOCKWISE to CLOSE.

3. To return actuator to normal operation, ﬁ rst check “% OPEN” on control panel. If value is 100%, return actuator to OPEN position as shown on the visual indicator. If value is 0%, return actuator to CLOSE position as shown on the visual indicator.

Handwheel Visual Indicator

Actuator

4 – 8

Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Purging with Dry Nitrogen

Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3.

PREPARATION

WARNING

serious injury or death.

WARNING

When working pressured systems, always wear safety glasses and/or face shield. Failure to comply

may result in serious injury.

1. Press “Stop” button to stop compressor unit, see Figure 4-7.

2. If equipped with equalizing solenoid, allow pressure in compressor unit to equalize to suction pressure, see Figure 4-8.

3. If equipped with manual suction bypass valve and it is not open, open suction bypass valve. Allow pressure in compressor unit to equalize to suction pressure.

4. Close suction and discharge shut-off valves to isolate the compressor unit from house system. Lockout/tagout valves.

5. Slowly open suction oil charging valve to depressurize compressor unit to atmosphere, see Figure 4-8. Keep valve in open position.

NOTE

Plugs are installed on bleed valves. Remove and install

plugs prior to and after bleeding. Ensure to keep valves

closed when removing and installing plugs.

6. Open discharge bleed valve to allow nitrogen to purge through compressor unit, see Figure 4-8.

7. Refer to PLC main screen for discharge pressure when purging.

PURGE

CAUTION

Do not purge compressor unit with oxygen. Failure to

comply may result in damage to equipment.

CAUTION

Do not allow compressor to spin while purging. Regulate purging pressure as needed. Failure to

comply may result in damage to equipment.

8. Connect purging hose from nitrogen cylinder to suction oil charging valve.

Discharge Status

Figure 4-7. PLC Main Screen

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Stop Button

4 – 9

Section 4 • Operation

NOTE

Purging is performed through the suction oil charging valve so that trapped gas can be pushed out of the compressor. This will help minimize metal surface oxidation of the compressor (due to the gas) while not

in service.

9. Purge compressor unit for 5 minutes. Check discharge pressure on PLC main screen to make sure pressure is increasing.

10. Close discharge bleed valve while still purging.

11. Observe discharge pressure through the PLC main screen. Allow pressure to build to approximately 10 psig.

View Rotate 180°

12. Once pressure is reached, stop purging and close suction oil charging valve. If pressure is greater than 10 psig, crack open discharge bleed valve, as needed, to slowly bleed the system to approximately 10 psig.

13. Wait 10 minutes to make sure there are no leaks and that the pressure is holding.

14. Remove purging hose from suction oil charging valve.

Equalizing Solenoid

for Suction Bypass

Suction Bypass Valve

(Manual)

View Rotate 180°

Figure 4-8. Suction Bypass Valve and Equalizing Solenoid

Suction Oil Charging Valve

Discharge Bleed Valve

4 – 10

Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Purging with Dry Gas

Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3.

PREPARATION

WARNING

serious injury or death.

WARNING

When working pressured systems, always wear safety glasses and/or face shield. Failure to comply

may result in serious injury.

NOTICE

To purge the compressor unit using a dry gas (i.e. methane), a purge line must be installed. If there is not enough purge pressure, connect purge line to a lower pressure line or to atmosphere. The purge line,

associated valves and gauges are not provided from the

factory and must be installed by the customer.

1. Refer to Figure 4-10 for recommended purge line design.

2. Press “Stop” button to stop compressor unit, see Figure 4-11.

3. If equipped with equalizing solenoid, allow pressure in compressor unit to equalize to suction pressure, see Figure 4-12.

4. If equipped with manual suction bypass valve and it is not open, open suction bypass valve. Allow pressure in compressor unit to equalize to suction pressure.

5. Close suction and discharge shut-off valves to isolate the compressor unit from house system. Lockout/tagout valves.

To Lower Pressure Line or Atmosphere. See NOTICE.

Shut-off Valve

Check Valve

Drain Valve

SUCTION INLET

002

PURGE LINE

PRESSURE

EQUALIZING LINE

001

COALESCING OIL RETURN LINE

Pressure Indicator Shut-off Valve

002

DRAIN

OIL CHARGE

PT 001

BLEED

MOTOR

005

001

1000W 1000W 1000W

QE 101QE102QE103

002

BLEED

OIL SEPARATOR

LG 002

004

COMPRESSOR

QE 007

DRAIN

DISCHARGE OUTLET

TE 002

REMOTE

OIL COOLER

007

VENT

003

DRAIN

Figure 4-10. Customer Purge Line

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

4 – 11

Section 4 • Operation

NOTE

Plugs are installed on bleed valves. Remove and install

plugs prior to and after bleeding. Ensure to keep valves

closed when removing and installing plugs.

6. Slowly open suction oil charging valve and bleed remaining pressure in compressor unit to atmosphere, see Figure 4-13. Leave suction oil charging valve in open position.

7. If equipped with pressure indicator on purge line, open shut-off valve to pressure indicator.

8. If not equipped with pressure indicator, refer to PLC main screen for discharge pressure when purging.

PURGE

CAUTION

Do not purge compressor unit with oxygen. Failure to

comply may result in damage to equipment.

CAUTION

Do not allow compressor to spin while purging. Regulate purging pressure as needed. Failure to

comply may result in damage to equipment.

9. Connect purging hose from gas cylinder to suction oil charging valve.

NOTE

in service.

10. Purge compressor unit for 4 minutes. Check pressure indicator or discharge status on PLC main screen to make sure pressure is increasing.

11. Close shut-off valve on purge line while still purging.

12. Observe discharge pressure of compressor unit through the PLC main screen.

13. Allow pressure to build to approximately 10 psig in the compressor unit.

14. Once pressure is reached, stop purging and close suction oil charging valve.

15. Wait 10 minutes to make sure there are no leaks and that the pressure is holding.

16. Remove purging hose from suction oil charging

valve.

Discharge Status

Stop Button

Figure 4-11. PLC Main Screen

4 – 12

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 4 • Operation

Suction Bypass Valve

(Manual)

Figure 4-12. Suction Bypass Valve and Equalizing Solenoid

View Rotate 180°

Equalizing Solenoid

for Suction Bypass

Suction Oil Charging Valve

View Rotate 180°

Figure 4-13. Suction Oil Charging Valve

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

4 – 13

Section 4 • Operation

Coalescing Oil Return Line Setup

Over time, oil will accumulate on the coalescing side of the oil separator. As a result, an oil return line with a shut-off valve, sight-glass, check valve and needle valve are installed between the coalescing side and compressor to return this oil back to the compressor.

To adjust the return ﬂ ow, proceed with the follow procedure:

NOTE

Do not fully open the needle valve unless directed by

Vilter Customer Service. Leaving the needle valve fully

open will reduce efﬁ ciency of the compressor unit.

1. Open shut-off valve on coalescing side of oil separator, see Figure 4-14.

2. While the unit is in operation, crack open needle valve and observe oil ﬂ ow through sight-glass.

3. Slowly open needle valve more until a small amount of oil is seen in the sight-glass.

NOTE

The sight-glass should never be full with oil.

4. Periodically check oil in the sight-glass and ensure that there is ﬂ ow.

Needle Valve

Coalescing Oil Return Line

Figure 4-14. Coalescing Oil Return Line

Check Valve

Sight-Glass

Shut-Off Valve

4 – 14

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Maintenance and Service Schedule

Follow this table for maintaining and servicing the compressor unit at hourly intervals.

60,000

55,000

50,000

45,000

40,000

)

(

35,000

30,000

25,000

Service Interval (Hours)

Table 5-1. Maintenance/Service Schedule

(Based on dry clean gas)

(2)

Inspection/

Maintenance

20,000

15,000

10,000

5,000

2,500

200

Oil Change Replace oil based on oil analysis report or visual contamination.

Oil sampling is recommended every 2 to 3 months for the ﬁ rst year. Thereafter, as required, increase

sampling time period if contamination of oil is unlikely or decrease sampling time period if contami-

Oil Analysis

----R--R--R--R

nation of oil is evident. Take an oil sample any time during operation If there’s reason to believe that

the oil is contaminated. For additional information on oil, refer to Oil and Oil Flow operation.

(3)

Oil Strainer IIIIIIIIIIIIII

Oil Filters

Coalescing Filter ----R--R--R--R

Coalescing Drain Line IIIIIIIIIIIIII

IIIIIIIIIIIIII

Suction Screen I - - I - I - I - I - I - I

Coupling Alignment

and Integrity

Motor (Compressor) See Motor Manual for proper lubrication procedures and service intervals.

Transducers IIIIIIIIIIIIII

RTDs IIIIIIIIIIIIII

-I-I-I-I-I-I-I

Slide valve calibration should be inspected monthly. Inspections can be performed through the

control panel. If a Non-Movement Alarm appears, calibrate immediately.

(6)

Compressor

Bearings -------------I

Slide Valve Motors

Group

Oil Circuit

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Unit

Compressor

(4) (5)

Control

Calibration

Compressor

I = Inspect S = Sampling R = Replace

(1) Vilter recommends that a Preventative Maintenance Program be developed by Vilter GC (Gas Compression) Service Center.

(2) Daily records should be kept on suction, discharge, oil pressures & temperatures, along with ensuring Temp Leaving Oil Separator is above Dew Point.

(3) Replace oil ﬁ lters when pressure drop reaches 7 PSID (maximum allowable pressure drop is 15 PSID).

(4) The life of the compressor will be increased by purging the compressor unit with dry nitrogen or sweet, dry natural gas at shutdown.

(5) Header drains should periodically be drained for liquid build-up to prevent compressor damage, see Piping in Section 3.

(6) Inspections include: gate rotor inspection, backlash measurement, shelf clearance, end play measurement (main rotor & gate rotor), gate rotor ﬂ oat, slide valve inspection.

5 – 1

Section 5 • Maintenance/Service

Maintaining Proper Operation

To ensure proper operation, the following items should be checked:

• Calibrate all transducer and RTDs.

• Check capacity and volume actuator calibration.

• Check fuses in the PLC panel.

• Check for loose wiring connections in the PLC panel.

• Check relay and contact operation for relays in the PLC panel.

• Verify the operation of the suction and discharge check valves.

• Check for correct rotation of all motors on the package (compressor, oil pump, and fan motors).

• Check that the piping to the oil cooler is correct.

• Check setup of soft starts and VFDs.

• Verify set points in the PLC.

• Check oil heater operation.

• Verify oil line check valve is installed for correct ﬂ ow .

• Check for loose bolts on the compressor unit. Tighten any loose bolts.

Compressor Unit Isolation for Maintenance/Service

WARNING

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in

serious injury or death.

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

NOTICE

Recover or transfer all gas vapor in accordance with local ordinances before opening compressor unit to

atmosphere.

The compressor unit must be isolated and depressurized to atmosphere prior to servicing.

1. Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

Suction By-Pass Valve

5 – 2

Figure 5-1. Suction By-Pass Valve Location (Manual) (1 of 2)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

2. If equipped with equalizing solenoid to control suction by-pass, allow solenoid to remain open until pressures equalize, see Figure 5-1 (2 of 2).

3. Turn motor and oil pump starter disconnect switches into the OFF position. Lockout/tagout disconnect switches.

4. If equipped with manual suction by-pass valve and it is not open, open suction by-pass valve to allow oil separator pressure to vent to low-side system pressure, see Figure 5-1 (1 of 2). Close suction bypass valve when complete.

5. Isolate the compressor unit by closing all valves to the house system. Lockout/tagout valves.

NOTE

If drain valves are installed on suction and discharge headers, open these valves too to remove build up

of liquid during shut-down periods.

6. Open any other valves that may trap liquid. Lockout/ tagout valves.

7. Recover or transfer all gas vapors.

8. Open discharge pressure bleed valve at block and bleed assembly and allow remaining pressure in oil separator to equalize to atmospheric pressure.

9. Servicing the compressor unit can proceed at this point. After servicing, ensure to perform a leak check, see Compressor Unit Leak Check procedure.

Compressor Unit Leak Check

The compressor unit must be checked for leaks after servicing to ensure a tight system.

CAUTION

Do not hydro test compressur unit. Failure to comply

may result in damage to equipment.

1. If servicing the compressor unit was completed, proceed to step 2. Otherwise, isolate the compressor unit from the house system, see Compressor Unit Isolation procedure.

2. Slowly pressurize compressor unit through suction oil charging port.

3. Check for leaks.

4. Typically, no evacuation is required for open loop systems. If dry nitrogen was used, it can be bled off to atmosphere.

5. If evacuation is required, evacuate from suction oil charging port.

6. Open all valves previously closed and close all valves previously opened. Remove tags as per the local lockout/tagout procedure.

7. Turn the motor and oil pump disconnect switches to the ON position.

8. The compressor unit can now be started, refer to Start-Up procedure in Section 4.

Line from Oil Separator

Shut-off

Line from Oil Separator to Shut-off Valve

Line from Needle Valve to Suction

Figure 5-1. Suction By-Pass Valve Location (Equalizing Solenoid) (2 of 2)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Valve

Line to Suction

Solenoid

Needle Valve

5 – 3

Section 5 • Maintenance/Service

Oil System Components

Oil Sampling

WARNING

serious injury or death.

WARNING

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in

serious injury or death.

Use Vilter Oil Analysis Kit (VPN 3097A) to collect an oil sample for analysis. For an example, see Figure 5-2. Fill out label for bottle. Place in mailing tube and seal with the preaddressed mailing label. Below are a few points to remember when taking a sample:

• Sample running compressor units, not cold units.

• Sample upstream of the oil ﬁ lter.

• Create speciﬁ c written procedures for sampling.

• Ensure sampling valves and devices are thoroughly ﬂ ushed prior to taking a sample.

• Ensure samples are taken as scheduled in the Maintenance and Service Schedule.

• Send samples immediately to the oil analysis lab after sampling, do not wait 24 hours.

NOTE

A copy of the oil analysis report is also sent to Vilter. See Appendices for a sample of the oil analysis report.

An oil analysis report will show the physical properties of the oil, such as:

• Water content

• Viscosity

• Acid number

• Particle count

• Antioxidant level

• Wear metals

• Contaminate/additive metals

5 – 4

Figure 5-2. Oil Analysis Kit

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Oil Charging

WARNING

Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply

may result in serious injury or death.

CAUTION

Do not add oil to the coalescent side of the oil separator. Failure to comply may result in damage to

equipment.

Normal oil level operating range must be maintained for optimum performance and to prevent damage to equipment. See Figure 4-1. for normal operating levels. There are a couple of ways to maintain oil, while the compressor unit is in operation and during shutdown.

Tool Required:

• Oil Pump, Maximum 2-3 GPM with Motor approved for Division 1 or Division 2 and with ability to overcome suction pressure.

1. Using a properly selected oil pump, connect oil pump to suction oil charging valve, see Figure 5-3.

2. Open suction oil charging valve and ﬁ ll oil separator to Normal Operating Level.

3. Once the Normal Operating Level has been reached, shut off the oil pump and close the valve. Disconnect and remove oil pump.

Charging During Shutdown:

During shutdown, if oil is to be added, charging can be performed through the drain valve located underneath the oil separator, see Figure 5-3. During shutdown, oil can be added to the Maximum Non-Operating Level. For shutdown procedure, see Compressor Unit Isolation procedure.

1. Using a properly selected oil pump, connect oil pump to oil separator drain valve.

2. Open oil separator drain valve and ﬁ ll oil separator to Maximum NON-Operating Level.

3. Once Maximum NON-Operating Level has been reached, shut off oil pump, close oil separator drain valve and remove oil pump.

Charging During Operation:

During operation, if the oil level is low, add oil to the operating compressor through the suction oil charging valve, see Figure 5-3. Pump oil into the compressor until the oil level reaches the normal operating level. Watch this level carefully to maintain proper operation. Never allow the oil to reach a level higher than the Maximum Operating Level, since this may impair the operation and efﬁ ciency.

Suction Oil Charging Valve

View Rotate 180°

Oil Drain Valve (Oil Separator)

Oil Drain Valve (Oil Cooler)

Oil Filter Shut-Off Valves

Figure 5-3. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

View From Back - View Rotate 180°

5 – 5

Section 5 • Maintenance/Service

Oil Draining

WARNING

Do not drain oil from drain valve while the compressor unit is running. Shutdown the unit and allow pressures to equalize to suction pressure prior to draining.

Failure to comply may result in serious injury.

The compressor unit must be shut down prior to draining due to high pressures in the oil system, see Compressor Unit Isolation procedure.

Draining can be performed through the drain valve located underneath the oil separator, see Figure 5-3. A drain valve is also provided underneath the shell and tube oil cooler.

Draining of the remote oil cooler can be performed at the remote oil cooler drain valves. If equipped with lower level drains on the supply and return lines, these too can be utilized for draining. For additional information, see Recommended Remote Air Cooled Oil Cooler Piping in Appendices.

Oil Filter Replacement

NOTE

Ensure to check the oil pressure drop and record it

daily.

If the compressor unit is equipped with only a single oil ﬁ lter, the compressor unit must be shut down prior to servicing, see Stopping/Restarting procedure in Section

If the compressor unit is equipped with dual oil ﬁ lters, then one oil ﬁ lter can be isolated and serviced one at a time during operation. Each oil ﬁ lter can have single or dual oil ﬁ lter elements depending on the size of com- pressor used, see Table 5-2 and Figure 5-4.

Table 5-2. Oil Filter Elements and Compressor Models

Oil Filter Element Qty. VSG/VSSG Models

Single Element 301 - 701

Dual Elements 751 - 3001

To replace an oil ﬁ lter element, continue with the follow- ing steps:

Parts Required:

• Oil Filter Element (VPN 1833G)

WARNING

Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply

may result in serious injury or death.

Change the oil ﬁ lter as outlined in the Maintenance and Service Interval, see Table 5-1. Maintenance & Service Interval.

Single Oil Filter Assembly Dual Oil Filter Assembly

Cover Flange

Spring Plate

Element

Canister

Outlet

Inlet

Figure 5-4. Oil Filter Assemblies (Single and Dual)

Cover Flange

REMOVAL

NOTE

Both outlet shut-off valves should be open. If the outlet valve is closed for the oil ﬁ lter that is not in operation, slowly open the outlet shut-off valve until fully open. This will help reduce a sudden pressure

drop when switching oil ﬁ lters for servicing.

Elements

Spring Plate

Element

Inlet

Centering Piece

Canister

Outlet

5 – 6

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Vent Valve

Drain Valve

Vent Valve

Drain Valve

Inlet Shut-Off Valves

Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves

1. If equipped with dual oil ﬁ lters, open inlet shut-off valve for non-operating oil ﬁ lter to put it into opera- tion, see Figure 5-5.

2. To isolate oil ﬁ lter for servicing, close inlet and out- let shut-off valves for the oil ﬁ lter.

NOTE

To reduce unwanted oil splash from a vent or drain valve, connect a hose to the valve port and direct

the gas and oil into a drain pan.

3. Slowly release pressure in the oil ﬁ lter canister by opening the vent valve. Allow pressures to equalize to atmosphere.

INSTALLATION

Ensure oil ﬁ lter element on the outlet side is fully

9. If equipped with single oil ﬁ lter element, install oil

10. If equipped with dual oil ﬁ lter elements, install two

11. Position spring plate in orientation noted during

NOTICE

Dispose of the oil in a appropriate manner following all Local, State and Federal ordinances regarding the

disposal of used oil.

4. Using an drain pan, open drain valve and allow the oil to completely drain from the oil ﬁ lter canister.

NOTE

Note orientation of components to aid in installation.

5. Remove bolts and nuts securing cover ﬂ ange to the oil ﬁ lter canister. Remove cover ﬂ ange and spring plate. Retain spring plate.

6. If equipped with a single oil ﬁ lter element, remove ﬁ lter element from oil ﬁ lter canister.

7. If equipped with dual oil ﬁ lter elements, remove two ﬁ lter elements and ﬁ lter element centering piece from oil ﬁ lter canister. Retain ﬁ lter element centering piece.

8. Thoroughly clean the oil ﬁ lter canister, spring plate and centering piece. Inspect spring plate and

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

12. Tighten nuts, see Appendix A.

13. Using dry nitrogen gas, pressurize oil ﬁ lter canister

14. Close the vent valve and drain valve.

15. Open outlet shut-off valve for the oil ﬁ lter that is not

16. Repeat for second oil ﬁ lter, as required.

Outlet Shut-Off Valves

centering piece, if damaged, replace as required.

seated on the outlet pipe when installed.

ﬁ lter element in canister in orientation noted during removal.

oil ﬁ lter elements and centering piece in orientation noted during removal.

removal and install bolts and nuts to secure cover ﬂ ange to oil ﬁ lter canister.

through vent valve and check for leaks.

in operation.

NOTE

5 – 7

Section 5 • Maintenance/Service

Oil Separator Vessel

Oil Separator Manhole Cover

Pipe Stub

Coalescing Filter

Centering Strap

Flat Washer

Nuts

Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly

Coalescing Filter Replacement

WARNING

Use appropriate lifting devices and additional personnel when lifting heavy components. Ensure lifting devices are capable of lifting the weight o the component. Use lifting points (i.e. bolt holes designated for lifting eye bolts) that are provided on the component. Failure to comply may result in

serious injury.

WARNING

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in

serious injury or death.

NOTE

For coalescing oil ﬁ lters (11-7/8 in. O.D.), a tubing (3/4 in. O.D. x 6 ft. long ) can be used to aid in

removal and installation of the element.

REMOVAL

1. Isolate the compressor unit, see Compressor Unit Isolation procedure.

5 – 8

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Hold-Down Rod

3/4 in. O.D. Tubing, 6 ft. long

2. If required, install lifting eyes on oil separator manhole cover, see Figure 5-6.

3. Secure appropriate lifting device to oil separator manhole cover.

4. Remove all bolts except top four bolts securing oil separator manhole cover to oil separator vessel.

5. Adjust lifting device as needed to hold weight of oil separator manhole cover.

6. Remove remaining four bolts and oil separator manhole cover from oil separator vessel.

7. Remove nuts, ﬂ at washer and cover plate securing coalescing oil ﬁ lter to hold-down rod.

8. With assistance of second person, remove coalescing ﬁ lter from oil separator vessel.

9. Repeat steps 7 and 8 to remove additional coalescing ﬁ lters, as required.

INSTALLATION

10. Install tubing over hold-down rod. Position tubing as far back as possible.

11. With assistance of second person, position coalescing element over tubing and through hole of centering strap.

12. Push coalescing ﬁ lter into vessel until fully seated

Section 5 • Maintenance/Service

on pipe stub.

13. Remove tubing.

14. Position cover plate and ﬂ at washer on hold-down rod on end of the coalescing ﬁ lter.

15. Install nut to secure ﬂ at washer and cover plate to coalescing ﬁ lter. Tighten nut to 25 ft-lbs.

16. Install second nut to prevent ﬁ rst nut from moving.

17. Repeat steps 10 to 16 for installing additional coalescing ﬁ lters.

18. Position oil separator manhole cover on oil separator vessel.

19. Install bolts to secure oil separator manhole cover to oil separator vessel.

20. Tighten bolts, see Appendix A.

21. Perform Compressor Unit Leak Check procedure.

Oil Pump Strainer

NOTICE

Dispose of the oil in a appropriate manner following

all Local, State and Federal ordinances regarding the

disposal of used oil.

To clean the oil pump strainer, proceed with the following steps.

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

WARNING

Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in

serious injury or death.

1. Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3. Close shut-off valves located before the strainer and at the oil ﬁ lter(s) inlet.

4. Position drain pan under drain valve.

5. Open strainer drain valve and allow oil to completely drain, see Figure 5-7.

6. Remove bolts securing strainer cover to strainer. Remove strainer cover, gasket and element. Retain gasket.

7. Inspect gasket for damage, replace as required.

8. Wash element in solvent and blow it with clean air.

9. Inspect element for damage, replace as required.

10. Clean strainer cavity with clean lint-free cloth.

11. Install in reverse order of removal. For torque speciﬁ cations, see Appendix A.

12. Close strainer drain valve.

13. Open shut-off valves.

14. Check replaced components for leaks.

15. Turn disconnect switches to the ON position for the compressor unit and oil pump motor starter, if equipped.

16. Start compressor unit.

View From Back of Oil Pump Strainer

Bolts Strainer CoverNuts

Strainer Drain Valve

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Oil Pump Strainer

Figure 5-7. Oil Pump Strainer and Drain Valve

5 – 9

Section 5 • Maintenance/Service

Drive Coupling (Form-Flex BPU) Hub Installation

On all single screw units, the coupling assembly is shipped loose and will have to be installed and aligned on site. This is to allow a check of proper electrical phasing and direction of motor rotation. The motor and compressor have been aligned from the factory with the coupling hubs already installed. Using a dial indicator for aligning is recommended.

NOTE

Drive coupling type and size can be determined by the information on the compressor nameplate when ordering; Order Number and Compressor

Model Number.

To install the coupling, proceed with the following steps:

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

1. Ensure disconnect switches are in the OFF position for the compressor unit and oil pump motor starter, if equipped.

2. If hubs are already installed on motor shaft and compressor shaft, proceed to Drive Center Member Installation and Alignment procedure.

3. If coupling assembly is already assembled, the lock nuts are not torqued. Remove lock nuts and bolts securing hubs to disc packs. Remove both hubs. Leave the disc packs attached to center member.

4. Clean hub bores and shafts. Remove any nicks or burrs. If bore is tapered, check for good contact pattern. If bore is straight, measure bore and shaft diameters to ensure proper ﬁ tment. The keys should have a snug side-to-side ﬁ t in the keyway

with a small clearance over the top.

NOTE

If hub position on shaft does not allow enough room to install bolts, install bolts and disc pack before

mounting hub on shaft.

Hubs come in two different types, straight bore and tapered bore. Tapered bore hubs have additional hardware. Typically, a compressor will have a tapered shaft and therefore use a tapered bore hub.

STRAIGHT BORE HUBS

5. For straight bore hubs, install key in keyway of shaft.

6. Install hub on shaft. If installing straight bore hubs on motor and compressor shafts, allow 1/16” gap between the outer face of the hub to the outer face of the shaft for both hub installation. This will allow some play when installing the spacer. If installing a straight bore hub and a taper bore hub, allow a 1/8” gap between the outer face of the straight bore hub to the outer face of the straight shaft, see Table 5-3.

7. Install clamping bolts in hub.

8. Tighten clamping bolts, see Table 5-4.

9. Install set screw in hub to secure key.

10. Tighten set screw, see Table 5-4. Repeat steps for second straight bore hub.

TAPERED BORE HUBS

11. For taper bore hubs, install key in keyway of shaft.

12. Install hub on shaft.

13. If lock washers are being used, install hub cap, lock washers and bolt on shaft.

14. If locking tab is being used, install hub cap, locking tab and bolt on shaft.

15. Tighten bolt and draw hub up shaft to a stop.

5 – 10

Coupling

Size

BP38U

BP41U

BP47U

BP54U

BP56U

Table 5-3. Shaft and Hub Distances

Shaft Gap for Tapered

Compressor &

Straight Motor Shaft

Combination

6.25”

(158.75 mm)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Shaft Gap for Straight

Compressor &

Straight Motor Shaft

Combination

5.125”

(130.18 mm)

Distance

Between Hub

Faces

5.00”

(127 mm)

Section 5 • Maintenance/Service

16. If locking tab is being used, bend locking tabs in gap towards shaft and around bolt.

17. Install set screw in hub cap to secure key in keyway of shaft.

18. Tighten set screw, see Table 5-4.

Drive Center Member Installation and Alignment

NOTE

Always adjust motor to the compressor. The

compressor is aligned to the frame.

19. Adjust motor position as needed to obtain a distance of 5” between both hub faces.

20. Soft Foot. The motor must sit ﬂ at on its base (+/-

0.002”). Any soft foot must be corrected prior to center member installation.

NOTE

If the driver or driven equipment alignment speciﬁ cation is tighter than these recommendations, the speciﬁ cation should be used. Also, be sure to compensate for thermal movement in the equipment. The coupling is capable of approximately four time the above shaft alignment tolerances. However, close alignment at installation will provide

longer service with smoother operation.

The ﬂ ex disc pack is designed to an optimal thickness

and is not to be used for axial adjustments.

21. Axial Spacing. The axial spacing of the shafts should

be positioned so that the ﬂ ex disc packs are ﬂ at when the equipment is running under normal operating conditions. This means there is a minimal amount of waviness in the ﬂ ex disc pack when viewed from the side. This will result in a ﬂ ex disc pack that is centered and parallel to its mating ﬂ ange faces. Move the motor to obtain the correct axial spacing, see Table 5-3 and Figure 5-8.

22. Angular Alignment. Rigidly mount a dial indicator on one hub or shaft, reading the face of the other hub ﬂ ange. Rotate both shafts together, making sure the shaft axial spacing remains constant. Adjust the motor by shimming and/or moving so that the indicator reading is within 0.002” per inch of coupling ﬂ ange, see Figure 5-9.

23. Parallel Offset. Rigidly mount a dial indicator on one hub or shaft, reading the other hub ﬂ ange outside diameter. Indicator set-up sag must be compensated for. Rotate both shafts together. Adjust the equipment by shimming and/or moving so that the indicator reading is within 0.002” per inch of the axial length between ﬂ ex disc packs, see Figure 5-9.

With the coupling in good alignment the bolts will ﬁ t through the holes in the ﬂ anges and the disc packs more easily.

NOTE

All bolt threads should be lubricated. A clean motor oil is recommended. On size 226 and larger, a link must be put on bolt ﬁ rst. Remove the disc pack alignment bolt. Proceed to mount the second disc

pack to the other hub in the same way.

Ensure that the beveled part of the washer is against

Hub Distance

Figure 5-8. Hub Distance (Axial Spacing)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

5 – 11

Section 5 • Maintenance/Service

Angular Alignment Parallel Offset

Figure 5-9. Angular Alignment and Parallel Offset

the disc pack.

24. Install bolts and locking nuts to secure both disc packs to center member.

25. Tighten locking nuts.

26. If room is required to install center member, adjust hub position accordingly. If both the motor and compressor hubs are straight bores, adjust either hubs. If one hub is tapered and the other a straight, adjust the straight bore hub.

27. Using additional supports supporting center member. Install bolts and locking nuts to secure center member to compressor hub.

28. Tighten locking nuts.

29. Position hubs, ensure distance between face of both hubs is 5”.

NOTE

If there is waviness with the disc pack installed, adjust

Table 5-4. Hub Clamp Bolt and Set Screw Torque Speciﬁ cations

Coupling

Series/Size

BH38U 4 1/4-28 12 (16) 3/8 10 (13)

BH41U

BH47U 4 3/8-24 49 (66) 1/2 20 (27)

BH54U 4 7/16-20 78 (106) 1/2 20 (27)

BH56U 4 1/2-20 120 (163) 5/8 40 (54)

DP42 4 1/2-20 120 (163) 1/2 20 (27)

# Bolts Size-Pitch

4 5/16-24 23 (31) 3/8 10 (13)

Clamping Bolt Set Screw

distance accordingly until disc pack is straight.

30. Install bolts and locking nuts to secure disc pack to motor hub.

31. Tighten locking nuts, see Table 5-4.

Table 5-5. Disc Pack Installation Torque

Speciﬁ cations

Coupling

Size

BP38U 5/16-24 22 (30)

BP41U

BP47U 9/16-18 120 (163)

BP54U 9/16-18 120 (163)

BP56U 9/16-18 120 (163)

Torque

ft-lbs (Nm)

Lock Nut

Size

7/16-20 55 (75)

Size

Tightening

Torque

ft-lbs (Nm)

Torque

ft-lbs (Nm)

5 – 12

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

32. Perform hot alignment. Run compressor unit and allow to warm up completely.

33. Power down compressor unit and re-check alignments. Loosen motor mounting nuts to add shims or to adjust alignments as required.

34. Install coupling guard.

Drive Coupling (Type C Sure-Flex) Replacement

Drive couplings that are the Type C Sure-Flex type, are always installed with a C-ﬂ ange between the compres- sor and motor. The coupling assembly alignments are built into the design and therefore, should not require

alignment.

Drive Coupling (Form-Flex BPU) Center Member and Hub Removal

Drive coupling type and size can be determined

To remove coupling assembly, proceed with the following steps:

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to

equipment.

by the information on the compressor nameplate when ordering; Order Number and Compressor

REMOVAL

To remove Type C Sure-Flex coupling, proceed with the following steps:

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to

WARNING

NOTE

Drive coupling type and size can be determined by the information on the compressor nameplate when ordering; Order Number and Compressor

Model Number.

1. Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3. Allow compressor, motor and surrounding components to cool prior to servicing.

4. Remove coupling guard.

5. Remove lock nuts and bolts securing disc pack to hub on compressor shaft.

6. If additional room is required to remove the center member, loosen clamping bolts on straight bore hub(s).

7. Move straight bore hub on shaft as required to allow center member removal.

8. Remove lock nuts and bolts securing disc pack to hub on motor shaft. Remove center member.

9. For straight bore hubs, remove clamping bolts and hub from shaft.

10. For tapered bore hubs, remove bolt, lock washers, large washer and hub from shaft.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

1. Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3. Allow compressor, motor and surrounding components to cool prior to servicing.

4. Remove C-ﬂ ange access cover.

Mark locations of hubs prior to removal.

5. Loosen set screw in motor hub securing key in keyway.

6. Loosen clamping bolts securing hub to motor shaft.

7. Pry hub up motor shaft for space to remove coupling sleeve.

8. Remove coupling sleeve from hub.

9. Remove hub and key from motor shaft.

10. Loosen set screw in compressor hub securing key in keyway.

11. Loosen clamping bolts securing hub from

NOTE

Model Number.

equipment.

NOTE

5 – 13

Section 5 • Maintenance/Service

compressor shaft.

12. Remove hub and key from compressor shaft.

INSTALLATION

13. Install key and hub on compressor shaft as noted during removal.

14. Install set screw in compressor hub to secure key in keyway, see Table 5-6,

15. Install clamping bolts to secure hub on compressor shaft. Tighten clamping bolts, see Table 5-6,

16. Install key and hub on motor shaft as noted during removal. Allow gap to install coupling sleeve.

17. Install coupling sleeve on hubs. Position hub on motor shaft on coupling sleeve as noted during removal.

18. Install set screw in compressor hub to secure key in keyway. Tighten set screw, see Table 5-6,

19. Install clamping bolts to secure hub to motor shaft. Tighten clamping bolts, see Table 5-6.

Table 5-6. Clamping Bolts and Set

Screw Torque Speciﬁ cations

Type C

Coupling

Size

6 13 (18)

8 23 (31)

9 23 (31)

10 50 (68)

11 50 (68)

ft-lbs (Nm)

Clamping

Bolts

13 (18)

Key Set

Screw

13 (18)

Compressor Replacement

Notify Vilter prior to performing a compressor replacement. See Warranty instructions in Section 7.

REMOVAL

To replace a compressor on a unit, proceed with the following steps:

NOTICE

Dispose of the oil in a appropriate manner following all Local, State and Federal ordinances regarding the

disposal of used oil.

1. Shut down and isolate the compressor unit, see Compressor Unit Isolation for Maintenance and Service procedure.

NOTE

Note location of cables to aid in installation.

2. Disconnect all cables from sensors on compressor and actuators.

3. Remove drive coupling, see appropriate Drive Coupling Replacement procedure.

4. If equipped with C-ﬂ ange, remove bolts securing C- ﬂ ange to compressor.

5. Remove center member, see Drive Coupling Removal procedure.

6. Using appropriate drain pan, drain oil by removing drain plugs from under compressor housing and discharge manifold. Allow oil to completely drain.

7. Remove all oil lines from the compressor.

8. Support suction line with appropriate supporting equipment.

9. Remove nuts and bolts securing suction strainer/ check valve assembly to suction stop valve and compressor.

10. Using appropriate lifting device, remove suction strainer/check valve assembly from compressor.

11. Remove nuts and bolts securing discharge pipe to compressor and oil separator, see Figure 5-10.

12. Remove discharge pipe and gaskets from compressor and oil separator.

13. Remove nuts, ﬂ at washers, lock washers and studs securing compressor to frame.

14. Remove any additional lines and/or components to allow removal of compressor as required.

15. Install appropriate lifting eyes on top of compressor.

16. Using appropriate lifting device and additional

5 – 14

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

personnel, remove compressor from frame.

17. Remove shims and spherical washers from compressor mounting locations.

18. Inspect shims and spherical washers for damage, replace as required.

INSTALLATION

19. Install shims and spherical washers on compressor mounting locations, see Figure 5-10.

20. Install appropriate lifting eyes on top of compressor.

21. Using appropriate lifting device, position compressor on compressor mounting locations on frame.

22. Loosely install studs, lock washers, ﬂ at washers and nuts to secure compressor to frame until alignment is correct.

23. Check compressor for soft foot. Add or remove shims as required until measurements are within +/- 0.002”.

24. Tighten nuts to secure compressor to frame, refer to Appendix A.

25. If equipped with C-ﬂ ange, install bolts to se- cure C-ﬂ ange to compressor. Tighten bolts, see Appendix A.

26. If equipped with C-ﬂ ange, install C-ﬂ ange coupling, refer to C-ﬂ ange Coupling Replacement procedure.

27. Install coupling, see Drive Coupling Installation and Alignment procedure .

28. Install coupling guard.

29. Install nuts and bolts to secure discharge pipe to oil separator and compressor.

30. Tighten nuts on ‘discharge pipe-to-compressor ﬂ ange’ ﬁ rst, then tighten nuts on ‘discharge pipe- to-oil separator ﬂ ange’, see Appendix A.

31. Install nuts to secure suction strainer/check valve assembly to compressor and suction stop valve.

32. Tighten nuts on ‘suction strainer/check valve assembly-to-compressor’ ﬁ rst, then tighten nuts on ‘suction strainer/check valve assembly-to-suction stop valve’, refer to Appendix A.

33. Install all lines to compressor.

34. Install all cables to sensors on compressor and actuator.

35. Perform leak check, see Compressor Unit Leak Check procedure.

Compressor

Nut Lock Washer

Flat Washer

Frame

Shim

Stud Flat Washer

Lock Washer Nut

Spherical Washer Assembly

Figure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown)

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

5 – 15

Section 5 • Maintenance/Service

Compressor Shaft Bearing Float Inspections

If ﬂ oat measurements are out of tolerance, contact Vilter Customer Service for further assistance.

BEARING AXIAL FLOAT INSPECTION

CAUTION

When taking the measurements, do not exceed

300 lbs of force at point of contact or damage may

result to the bearings.

DETERMINE MAXIMUM APPLIED FORCE

To determine maximum applied force, take maximum applied force at hub/shaft multiplied by length of A and divide by length B. This is the maximum force that should be applied on the lever.

(Applied Force x A)/B = Applied Force (Maximum)

So, using a 36” (or 1 m) lever with pivot space of 6” (or 15 cm) would make the maximum applied force to be 60 lbf (or 235 N). Calculation is as follows:

(300 lbf x 6”)/30” = 60 lbf (Max. Applied Force)

(1335 N x 15 cm)/85 cm = 235 N (Max. Applied Force)

Force at

Applied

Force

Hub/Shaft

Lever

motor and use the lever arm to push the input shaft towards the compressor. Record measurement

5. Add both measurements. If measurement is out of allowable tolerance shown in Table 5-7, the bearing may need to be replaced. Contact Vilter Customer Service.

BEARING RADIAL FLOAT INSPECTION

6. Install dial indicator to the compressor frame and zero indicator, see Figure 5-12.

NOTE

Do not exceed maximum applied force. For maximum applied forces of all compressor models,

see Table 5-7.

7. Place lever arm and fulcrum underneath hub and push hub upwards. Record measurement.

8. If measurement is out of allowable tolerance shown in Table 5-7, the bearing may need to be replaced. Contact Vilter Customer Service.

Top Vie w

Shaft being pushed by use of lever.

Direction of

shaft movement.

Rigidly attach dial indicator. Position on axis of compressor.

Wooden Block

Pivot Point

or Fulcrum

As a quick reference, Table 5-7 shows maximum applied forces for 36” lever with 6” pivot for all compressor models.

MEASURE

To inspect bearing axial ﬂ oat, proceed with the following steps:

1. Remove center member, see appropriate Drive Coupling Replacement procedure.

2. Install dial indicator to the compressor frame and zero indicator, see Figure 5-11.

3. Place lever arm and fulcrum behind compressor coupling half and push the coupling towards the motor. Record measurement.

4. Re-zero indicator, now position the fulcrum on the

5 – 16

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Applied Force

Shaft being pushed by use of lever.

Rigidly attach dial indicator. Position on axis of compressor.

Direction of

shaft movement.

Wooden block or fulcrum

Top Vie w

Small wooden block or fulcrum.

Applied Force

Figure 5-11. Bearing Axial Float Inspection

Section 5 • Maintenance/Service

Table 5-7. Maximum Bearing Float

Max.

Force

at Hub/

Shaft

lbf (N)

300

(1335)

100

(444)

150

(667)

150

(667)

200

(890)

300

(1335)

400

(1780)

600

(2670)

Compressor

Model

All

151, 181, 201, 152, 182, 202,

301, 361, 401

501, 601, 701

291, 341, 451,

601

751, 901

791, 891,

1051, 1201,

1301

1501, 1551, 1801, 1851,

2101

2401, 2601,

2801, 3001

Max. Axial Float

in. (mm)

0.002

(0.051)

Max.

Radial

Float

in. (mm)

0.006

(0.152)

0.007

(0.178)

0.007

(0.178)

0.006

(0.152)

0.006

(0.152)

0.007

(0.178)

0.006

(0.152)

Max.

Applied

Force

(36” Lever, 6”

Pivot)

lbf (N)

(267)

(89)

(133)

(178)

(267)

(356)

120

(534)

Gate Rotor Float and Gate Rotor Bearing Float Inspection

GATE ROTOR FLOAT INSPECTION

To inspect gate rotor ﬂ oat and bearing ﬂ oat, proceed with the following steps:

1. Remove center member, see appropriate Drive Coupling Replacement procedure.

2. Remove the side covers from compressor.

3. Position gate rotor blade and damper pin at 90° to the main rotor, see Figure 5-13.

Dial Indicator

Gate Rotor

Gate Rotor Blade

Support

Side View

Shaft being pushed by use of lever.

Rigidly attach dial indicator.

Direction of shaft movement.

Applied Force

Figure 5-12. Bearing Radial Float Inspection

Damper Pin and Bushing

Main Rotor

Damper Pin

Bushing

Float

Figure 5-13. Gate Rotor Float

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5 – 17

Section 5 • Maintenance/Service

NOTE

Measurements can be an additional 0.020” higher than ﬂ oat dimensions on Table 5-8. If measurement is an additional 0.030” greater than ﬂ oat dimensions,

contact Vilter for further assistance.

Total movement of damper pin in bushing is the

gate rotor ﬂ oat.

4. Using dial indicator, take measurement of gate rotor ﬂ oat. Measurement should not exceed values as noted above.

Table 5-8. Gate Rotor Float

Model

VSSG 291-601 0.045 (1.143)

VSG 301-401

VSG 501-701 0.045 (1.143)

VSG 751-901 0.055 (1.397)

VSG 1051-1301 0.060 (1.524)

VSG 1551-2101 0.060 (1.524)

VSG 2401-3001 0.060 (1.524)

Some movement between blade and support is necessary to prevent damage to the compressor blade; however at no time should the blade uncover

the support.

5. Inspect main rotor and gate rotor for abnormal wear due to dirt or other contaminants. If damaged, replace gate rotor and/or main rotor.

Float

in. (mm)

0.045 (1.143)

NOTE

GATE ROTOR BEARING FLOAT INSPECTION

6. Using dial indicator, position a dial indicator on the gate rotor, see Figure 5-14.

Side View

Gate rotor bearing float being measured.

Wooden block to prevent damage to gate rotor blade.

Direction of rotor movement. Axial force at gate rotor to not exceed 100 lbs.

Applied

Force

Rigidly attach dial indicator.

Use bolt for fulcurm.

Figure 5-14. Gate Rotor Bearing Float

7. Use a lever arm pivoting on a bolt with a small block of wood against the gate rotor blade to protect the blade.

8. Gently apply pressure to lever and take measurement. Maximum amount of gate rotor bearing ﬂ oat should not exceed 0.002” (0.051 mm).

9. Install gate rotor cover.

10. Install center member, see Drive Coupling Replacement procedure.

11. Perform compressor unit leak check, see Compressor Unit Leak Check procedure.

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Section 5 • Maintenance/Service

Gate Rotor and Support Clearance

When measuring, push the gate rotor against the pin to remove ﬂ oat.

1. Place a straight edge along the side of the gate rotor, see Figure 5-16.

2. Measure the gap from the straight edge to the peak of the gate rotor support. For minimum distance, see Figure 5-15.

3. Repeat steps 1 to 2 to check gap along entire gate rotor edge on both sides.

Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

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Section 5 • Maintenance/Service

Gate Rotor

Support

Gate Rotor

Support

Straight Edge

Gate Rotor

Support

Gate Rotor

Straight Edge

5 – 20

Figure 5-16. Gate Rotor and Support Clearance - Measuring

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except

the shim pack.

9. Hold gate rotor support with a suitable wrench on the ﬂ ats provided near the roller bearing housing.

VSG 301-701 Compressors)

10. Remove the inner retainer bolts and retainer.

The following table lists the gate rotor tool sets needed to remove and install gate rotor assemblies.

Table 5-9. Gate Rotor Tool Sets

Model Tool Set VPN

VSSG 291-601 A25205B

VSG 301-401 N/A

VSG 501-701 A25205B

VSG 751-1301 A2520 5C

VSG 1551-2101 A25205E

VSG 2401-3001 A25205F

REMOVAL

1. Remove center member, see appropriate Drive Coupling Replacement procedure.

NOTE

All parts must be kept with their appropriate side and not mixed when the compressor is reassembled.

2. Remove two upper bolts from side cover

3. Install guide studs in holes.

NOTE

There will be some oil drainage when the cover is

removed.

4. Remove remaining bolts and side cover.

5. Turn main rotor so a driving edge of any one of the main rotor grooves is even with the back of the gate rotor support.

NOTE

The gate rotor stabilizer is designed to hold the gate rotor support in place and prevent damage to the gate rotor blade as the thrust bearings and housing

is being removed.

6. Insert gate rotor stabilizer. The side rails are not required on VSSG 291 thru 601. For the VSG 751 thru 901 and VSG 1051 thru 1301 compressors, use the side rails and assemble to the gate rotor stabilizer as stamped. For the VSG 1551 thru 2101, use the side rails and assemble to the gate rotor stabilizer.

7. Remove hex head bolts and socket head bolts from thrust bearing cover.

8. Re-install two bolts into the threaded jacking holes to assist in removing thrust bearing cover. Retain

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

11. To remove the thrust bearing housing, install thrust bearing removal and installation tool with smaller puller shoe. Turn the jacking screw clockwise. The thrust bearings and housing assembly will be pulled off the shaft and out of the frame.

12. Remove bolts from roller bearing housing.

13. Re-install two bolts into jack bolt holes provided in housing to aid in removal.

14. To remove the gate rotor support, carefully move support in the opposite direction of rotation and tilt roller bearing end towards the suction end of the compressor. The compressor input shaft may have to be turned to facilitate the removal of the gate rotor support. On dual gate compressor units, repeat the procedure for the remaining gate rotor support assembly.

INSTALLATION

15. Install gate rotor support by carefully tilting the roller bearing end of the gate rotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gate rotor support. Install gate rotor stabilizer. The gate rotor stabilizer (901) will hold the gate rotor support in place as the thrust bearing housing is being installed. If the gate rotor support is not restricted from moving, the gate rotor blade may be damaged.

16. Install the roller bearing housing (112) with a new O-ring (141).

17. Tighten bolts (152), see Appendix A.

18. When installing the thrust bearing housing (113), a new O-ring (142) must be used when the housing is installed, see Figure 5-19. Lubricate the outside of the housing and bearings with clean compressor oil to aid in the installation. Due to the ﬁ t of the bearings on the gate rotor shaft, the thrust bearing removal and installation tool with the pusher shoe must be used. Turn the jacking screw clockwise. This will push the thrust bearings onto the shaft and push the housing assembly into the frame. Install the inner retainer (115) and bolts (151) using Loctite® 242 thread locker. Tighten bolts, see Appendix A.

19. Set clearance between gate rotor blade and shelf.

20. Place a piece of 0.003”-0.004” shim stock between gate rotor blade and shelf.

5 – 21

Section 5 • Maintenance/Service

For VSSG 291-601 compressors, do not use side rails.

901A

For VSG 751/901 and 1051-1301compressors, use side rails and assemble gate rotor stabilizer as stamped.

901B

901C

NOTE

This measurement determines the amount of shims

needed for the correct clearance.

21. Measure depth from top of compressor case to top of thrust bearing housing.

22. Use factory installed shim pack (106) and bearing housing cover (116) without the O-ring (143).

NOTE

Replacement blades are precisely the same dimensionally as blades installed originally at factory: Therefore, the same amount of shims will

be required for replacement blades.

Use ﬂ ats provided on gate rotor support to prevent rotation when removing bearing retainer.

Position leading edge of main rotor groove ﬂ ush with or slightly below back of gate rotor support.

Figure 5-17. Gate Rotor Assembly Removal

and Tools

5 – 22

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 5-18. Gate Rotor Assembly Removal

Section 5 • Maintenance/Service

23. Check the clearance between the entire gate rotor blade and the shelf, rotate the gate rotor to ﬁ nd the tightest spot. It should be between 0.003-0.004“ (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf, see Figure 5-20.

24. After clearance has been set install a new O-ring (143) on bearing housing cover, install cover and tighten the bolts to the recommended torque value.

25. Install side cover with a new gasket. Tighten the bolts to the recommended torque value. The unit can then be evacuated and leak checked.

Check for 0.003-0.004” (0.076- 0.102 mm) clearance between

gate rotor blade and partition.

Figure 5-19. Gate Rotor Assembly and Tools

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 5-20. Gate Rotor and Shelf Clearance

5 – 23

Section 5 • Maintenance/Service

Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY)

REMOVAL

The removal of the gate rotor assembly for the VSG 301701 compressors is similar for the VSG 901- 2101 compressors except that the inner races are secured to the stationary bearing spindle.

1. Remove center member, see appropriate Drive Coupling Replacement procedure.

2. Remove the upper bolt from the side cover and install a guide stud in the hole.

3. Remove remaining bolts and side cover. There will be some oil drainage when the cover is removed.

4. The side cover that contains the suction strainer should have the suction line properly supported before the bolts securing the line to the cover can be removed. After the line is removed, the cover can be removed per paragraph B.

5. Turn the main rotor so the driving edge of the groove is between the top of the shelf or slightly below the back of the gate rotor support. At this point install the gate rotor stabilizing tool.

6. Remove plug on the thrust bearing housing. Loosen the socket head cap screw that is located underneath the plug. This secures the inner races of the thrust bearings to the spindle.

7. Remove bolts that hold the thrust bearing housing to the compressor. Insert two of the bolts into the threaded jacking holes to assist in removing the bearing housing from the compressor. When the housing is removed, there will be shims between the spindle and thrust bearings. These control the clearance between the shelf and gate rotor blades. These must be kept with their respective parts for that side of the compressor.

8. Remove the bolts from the roller bearing housing. After the bolts have been removed, the housing can be removed from the compressor.

9. To remove the gate rotor support, carefully move the support opposite the direction of rotation and tilt the roller bearing end towards the suction end of the compressor. The compressor input shaft may have to be turned to facilitate the removal of the gate rotor support. On dual gate versions, repeat the procedure for the remaining gate rotor support assembly.

bearing end of the gate rotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gate rotor support.

11. Install the roller bearing housing with a new O-ring. Tighten the bolts to the recommended torque value.

12. Install the spindle with shims and O-ring, tighten bolts, see Appendix A. Measure the clearance between the shelf and blade.

13. Check the clearance between the entire gate rotor blade and the shelf, rotate the gate rotor to ﬁ nd the tightest spot. It should be between 0.003-

0.004“ (0.076-0.102 mm). Make adjustments, if

INSTALLATION

10. Install the gate rotor support. Carefully tilt the roller

5 – 24

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Figure 5-21. Gate Rotor Assembly Breakdown

Section 5 • Maintenance/Service

necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf.

14. Once the clearance is set remove the spindle. Install new O-ring, apply Loctite 242 thread locker to the socket head cap screw clamping the thrust bearings to the spindle. Torque all bolts, see Appendix A.

15. Install side covers with new gaskets. Tighten bolts, see Appendix A. The unit can now be evacuated and leak checked.

Check for 0.003-0.004” (0.076- 0.102 mm) clearance between

gate rotor blade and partition.

Figure 5-23. Gate Rotor and Shelf Clearance

Figure 5-22. Gate Rotor Thrust Bearing

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Section 5 • Maintenance/Service

Gate Rotor Disassembly

1. To perform gate rotor disassembly, remove gate rotor from compressor, see Gate Rotor Assembly Replacement procedure (All VSG-VSSG Compressors Except VSG 301-701 Compressors) or Gate Rotor Assembly procedure (VSG 301-701 Compressors ONLY).

GATE ROTOR BLADE REMOVAL

2. Remove the snap ring and washer from the gate rotor assembly. Lift gate rotor blade assembly off the gate rotor support, see Figure 5-24.

3. Check damper pin and bushing for excessive wear. Replace if required.

GATE ROTOR BLADE INSTALLATION

4. Install damper pin bushing (120) in gate rotor blade (111) from the back side of the blade. Be sure bushing is fully seated.

5. Place blade assembly on gate rotor support. Locating damper over pin.

6. Install washer (119) and snap ring (130) on gate rotor assembly. The bevel on the snap ring must face away from the gate rotor blade. After the gate rotor blade and support are assembled, there should be a small amount of rotational movement between the gate rotor and support.

5 – 26

Figure 5-25. Gate Rotor Blade Installation

Figure 5-24. Gate Rotor Blade Assembly

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 5 • Maintenance/Service

GATE ROTOR THRUST BEARING REMOVAL

For removal of thrust bearings on VSG units:

7. Remove bolts (150) from the clamping ring (114), see Figure 5-26.

8. Remove thrust bearing clamping ring.

9. Remove thrust bearings (126) from housing (113).

For removal of thrust bearings on VSSG units:

10. Remove retaining ring from gate rotor support.

11. Remove bearings from support.

12. Remove bearing retainer from inner race.

sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the gate rotor support.

17. Install the bearing retaining snap ring.

Figure 5-26. Gate Rotor Thrust Bearing

GATE ROTOR THRUST BEARING INSTALLATION

For installation of thrust bearings on VSG and VSSG units:

13. Install thrust bearings (126) in the housing so the bearings are face to face. The larger sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the housing.

14. Center the bearing retainer ring on housing, use Loctite® 242-thread locker and evenly tighten the bolts to the recommended torque value, see Figure 5-27.

For installation of thrust bearings on VSG 301- 701 units:

15. Install retainer in the back of the inner race of one of the thrust bearings. The back of the inner race is the narrower of the two sides.

16. The bearing with the retainer should be placed in the housing ﬁ rst, retainer towards the support. Install the second bearing. The bearings should be positioned face to face. This means that the larger

Figure 5-27. Thrust Bearing Installation

GATE ROTOR ROLLER BEARING REMOVAL

18. Remove the snap ring (131), which retains the roller bearing in the bearing housing, see Figure 5-28.

19. Remove the roller bearing (125) from the bearing housing (112).

20. Use a bearing puller to remove the roller bearing race (125) from the gate rotor support (110).

GATE ROTOR ROLLER BEARING INSTALLATION

21. Match up the part numbers on the inner race to the part numbers outer race. Press the bearing race (numbers visible) onto the gate rotor support.

22. Install the outer bearing into the bearing housing so the numbers match the numbers on the inner race. Install the snap ring retainer in the housing.

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5 – 27

Section 5 • Maintenance/Service

The bevel on the snap ring must face away from the roller bearing.

Figure 5-28. Roller Bearing Assembly

Restarting procedure in Section 4.

2. Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3. Allow compressor, motor and surrounding components to cool prior to servicing.

4. Disconnect connectors from actuator.

NOTE

Note orientation of components to aid in installation.

5. Remove screws and lock washers securing actuator assembly to actuator mount.

6. Remove actuator assembly from actuator mount.

INSTALLATION

CAUTION

When installing the slide valve actuator assembly,

loosen locking collar down the shaft. Do not use a

screwdriver to pry locking collar into position.

Slide Valve Actuator Assembly Replacement

To replace slide valve actuator assembly, proceed with the following steps:

REMOVAL

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to

equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or

damage to equipment.

NOTE

This procedure is applicable to both capacity and

volume slide valve actuator assemblies.

7. Position actuator assembly on mount as noted in removal.

8. Install lock washers and screws to secure actuator assembly to actuator mount.

9. Tighten screws, see Appendix A.

10. Connect connectors to actuator assembly.

11. Calibrate actuator assembly, see Slide Valve Calibration procedure in Section 4.

1. Shut down the compressor unit, refer to Stopping/

5 – 28

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Section 5 • Maintenance/Service

Command Shaft Assembly Replacement

REMOVAL

NOTE

The following steps can be used to remove or install either the capacity or volume command shaft

assemblies.

1. Shut down and isolate compressor unit, see Compressor Unit Shutdown and Isolation procedure.

2. Remove actuator, see Actuator Assembly Replacement procedure.

3. Remove four socket head cap screws (457) and Nord-Lock washers (477) securing mounting plate (415) to manifold.

4. The command shaft and mounting plate may now be removed from the compressor.

cover.

5. Seal with stationary carbon face (219B) and rotating mirror face (219C).

INSTALLATION

5. Install the command shaft assembly with a new O-ring (446) on the manifold. Make sure that the command shaft tongue is engaged in the cross shaft slot. Rotate the bearing housing so the vent holes point down, this will prevent water and dust from entering the vents.

6. Install the actuator mounting plate with the four socket head cap screws and Nord-Lock washers securing it with proper torque.

7. Perform leak check, see Compressor Unit Leak Check procedure.

Command Shaft Seal Replacement

REMOVAL

1. Remove bolts (281) holding the shaft seal cover (218). Insert two of the bolts into the threaded jacking holes to assist in removing the cover. There will be a small amount of oil drainage as the cover is removed.

2. Remove the rotating portion of the shaft seal (219C).

3. Remove oil seal (230) from cover.

4. Remove the stationary portion of the shaft seal (219B) from the seal cover using a brass drift and hammer to tap it out from the back side of the seal

Figure 5-29. Command Shaft Seal

INSTALLATION

CAUTION

Care must be taken when handling the shaft seal and

mirror face so it is not damaged. Do not touch the

carbon or mirror face as body oil and sweat will cause

the mirror face to corrode.

NOTE

When replacing the stationary members of the seal on the VSSG 291 thru VSSG 601 the roll pin in the cover is used only with the seal assembly having a stationary mirror face. If a seal assembly with a stationary carbon face is installed, the roll pin must

be removed.

6. To install the carbon cartridge part of the seal in the seal cover; clean the seal cover, remove protective plastic from the carbon cartridge, do not wipe or touch the carbon face. Lubricate the sealing O-ring with clean compressor lubricating oil. If applicable, align the hole on the back of the carbon cartridge with the dowel pin in the seal cover. Install cartridge using seal installation tool or similar (see tool lists).

7. Wipe clean, the compressor input shaft and the

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

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Section 5 • Maintenance/Service

shaft seal cavity in the compressor housing. Apply clean compressor oil to the shaft seal seating area on input shaft.

8. Lubricate the inside area of the rotating seal with clean compressor lubricating oil, do not wipe or touch the face of the rotating portion of the seal. Align the slot in the rotating seal with the drive pin on the compressor input shaft, see Figure 5-30. Carefully push the seal on, holding onto the outside area of the seal until the seal seats against the shoulder on the input shaft. Make sure the seal is seated against the shoulder. If the seal is not fully seated against the shoulder, the shaft seal carbon will be damaged when the seal cover is installed.

5 – 30

Figure 5-30. Command Shaft Seal Installation

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 6 • Troubleshooting

Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2)

Problem Reason Solution

The actuator cannot be calibrated or exit calibration mode

The actuator goes into calibration mode spontaneously

Dirt or debris is blocking one or both optocoupler slots

The photochopper fence extends less than about half way into the optocoupler slots

The white calibrate wire in the grey Turck cable is grounded

Dirt and/or condensation on the position sensor boards are causing it to malfunction

The calibrate button is stuck down Try to free the stuck button.

The position sensor has failed

Push button is being held down for more that ¾ second when going through the calibration procedure

The white calibrate wire in the grey Turck cable is grounding intermittently

A very strong source of electromagnetic interference (EMI), such as a contactor, is in the vicinity of the actuator or grey cable

Clean the optocoupler slots with a Q-Tip and rubbing alcohol.

Adjust the photochopper so that the fence extends further into the optocoupler slots. Make sure the motor brake operates freely and the photochopper will not contact the optocouplers when the shaft is pressed down.

Tape the end of the white wire in the panel and make sure that it cannot touch metal

Clean the boards with an electronics cleaner or compressed air.

Replace the actuator.

Depress the button quickly and then let go. Each ¾ second the button is held down counts as another press.

Tape the end of the white wire in the panel and make sure that it cannot touch metal.

Install additional metal shielding material between the EMI source and the actuator or cable.

There is an intermittent failure of the position sensor

The actuator goes into calibration mode every time power is restored after a power loss

The actuator does not transmit the correct position after a power loss

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

The motor brake is not working properly (see theory section above.)

The motor was manually moved while the position sensor was not powered.

The motor brake is not working properly

The position sensor’s EEPROM memory has failed

Replace the actuator.

Get the motor brake to where it operates freely and recalibrate.

Recalibrate.

Get the motor brake to where it operates freely and then recalibrate.

Replace the actuator.

6 – 1

Section 6 • Troubleshooting

Table 6-1. Slide Valve Actuator Troubleshooting Guide (2 of 2)

Problem Reason Solution

The motor was manually moved while the position sensor was not powered.

Recalibrate.

The actuator does not transmit the correct position after a power loss

There is a rapid clicking noise when the motor is operating

The motor operates in one direction only

The motor will not move in either direction

The motor runs intermittently, several minutes on, several minutes off

The motor brake is not working properly

The position sensor’s EEPROM memory has failed

The photochopper is misaligned with the slotted optocouplers

The photochopper is positioned too low on the motor shaft.

A motor bearing has failed Replace the actuator.

There is a loose connection in the screw terminal blocks

There is a loose or dirty connection in the yellow Turck cable

The position sensor has failed Replace the actuator.

There is a broken motor lead or winding

The thermal switch has tripped because the motor is overheated

Any of the reasons listed in “The motor operates in one direction only”

The command shaft is jammed Free the command shaft.

Broken gears in the gearmotor Replace the actuator.

Blown relay or fuse.

Motor is overheating and the thermal switch is tripping

Get the motor brake to where it operates freely and then recalibrate.

Replace the actuator.

Try to realign or replace the actuator.

Adjust the photochopper so that the fence extends further into the optocoupler slots.

Tighten.

Clean and tighten.

Replace the actuator.

The motor will resume operation when it cools. This could be caused by a malfunctioning control panel. Consult the factory.

See above.

Check and replace blown relay and/ or fuse.

This could be caused by a malfunctioning control panel. Consult the factory.

The motor runs sporadically

The motor runs but output shaft will not turn

6 – 2

Bad thermal switch Replace the actuator.

Any of the reasons listed in “The motor will not move in either direction”

Stripped gears inside the gear motor or the armature has come unpressed from the armature shaft

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

See above.

Replace the actuator.

Section 6 • Troubleshooting

Slide Valve Actuators communicate problems discovered by internal diagnostics via LED blink codes. Only one blink code is displayed, even though it is possible that more than one problem has been detected.

Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2)

Flash Pattern Meaning

*=ON

_=OFF

*_*_*_*_*_*_*_*_*_*_*_

*___*___*___*___*___

*__*________________

Calibration step 1

Calibration step 2

This indicates a zero span. This error can only occur during calibration. The typical cause is forgetting to move the actuator when setting the upper limit of the span. If this is the case, press the blue button to restart the calibration procedure. This error can also occur if either or both of the slotted optocouplers are not working. If this is the case, the slide valve actuator will have to be replaced.

The operation of the slotted optocouplers is tested as follows:

1. Manually rotate the motor shaft until the aluminum photochopper fence is not blocking either of the optocoupler slots.

2. Using a digital multi-meter, measure the DC voltage between terminal 3 of the small terminal block and TP1 on the circuit board (see Note 1). You should measure between 0.1 and 0.2 Volts.

3. Next, measure the DC voltage between terminal 3 and TP2 on the circuit board. You should measure between 0.1 and 0.2 Volts.

This indicates a skipped state in the patterns generated by the optocouplers as the motor moves. This error means that the slide valve actuator is no longer transmitting accurate position information. The actuator should be recalibrated as soon as possible. This code will not clear until the actuator is recalibrated.

This code can be caused by:

*__________________

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

1. The motor speed exceeding the position sensors ability to measure it at some time during operation. A non-functioning motor brake is usually to blame.

2. The actuator is being operated where strong infrared light can falsely trigger the slotted optocouplers, such as direct sunlight. Shade the actuator when the cover is off for service and calibration. Do not operate the actuator with the cover off.

6 – 3

Section 6 • Troubleshooting

Table 6-2. Slide Valve Actuator LED Blink Codes (2 of 2)

Flash Pattern Meaning

The motor has overheated. The actuator motor will not run until it cools. Once the motor cools, the actuator will resume normal operation.

Motor overheating is sometimes a problem in hot and humid environments when process conditions demand that the slide valve reposition often. Solutions

*__*__*____________

are available; consult your Vilter authorized distributor for details.

Another possible cause for this error is a stuck motor thermal switch. The thermal switch can be tested by measuring the DC voltage with a digital multi-meter between the two TS1 wire pads (see Note 2). If the switch is closed (normal operation) you will measure 0 Volts.

The 24V supply is voltage is low. This will occur momentarily when the actuator is powered up and on power down.

********************

If the problem persists, measure the voltage using a digital multi-meter between terminals 3 and 4 of the small terminal block. If the voltage is >= 24V, replace the actuator.

The EEPROM data is bad. This is usually caused by loss of 24V power before the calibration procedure was completed. The actuator will not move while this error code is displayed. To clear the error,

_*******************

calibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible causes are:

1. The EEPROM memory in the micro-controller is bad.

2. The large blue capacitor is bad or has a cracked lead.

*****____*__________ Micro-controller program failure. Replace the actuator.

*There are two versions of slide valve actuators, version A and B. Only version B is able to display LED blink codes. Slide valve actuator version B can be distinguished by only having a single circuit board as supposed to two circuit boards in version A.

Note 1: TP1 and TP2 are plated-thru holes located close to the slotted optocouplers on the board. They are clearly marked on the board silkscreen legend.

Note 2: The TS1 wire pads are where the motor thermal switch leads solder into the circuit board. They are clearly marked on the board silkscreen legend and are oriented at a 45 degree angle.

6 – 4

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 6 • Troubleshooting

Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3)

Problem Solution

• After failing to start compressor with “Prelube Oil Pump Inhibit”, ﬁ rst allow Discharge pressure, Oil Filter In pressure and Out pressure to equalize. Then restart compressor. If compressor fails to start due to low oil pressure, continue troubleshooting with items below.

• Reset Prelube Oil Pressure Setpoint in Alarms and Trip Setpoints screen to lowest recommended setpoints.

• Check calibration of oil manifold transducer, discharge pressure transducer, and suction transducer.

Low Oil Pressure at Start

Low Run Oil Pressure

Oil ﬂ ow or oil pressure problems

• Check for correct oil pump motor rotation and operation.

• Ensure transducer isolation valves are open.

• Verify that the correct transducer ranges are selected.

• Check to see all oil line valves are open except the oil dump valve used to ﬁ ll the lines and oil cooler.

• Check oil strainer for dirt.

• Check oil ﬁ lter pressure drop.

• Check “Prelube Oil Pump Time Limit” setpoint is sufﬁ cient in Compressor Timer Setpoints screen.

• Prelube pressure is manifold pressure minus discharge pressure.

• Check solutions in “Low Oil Pressure at Start”.

• Check that there is proper discharge pressure ratio to create differential pressure, otherwise oil pressure can’t be maintained. Oil pressure is manifold oil pressure minus the suction pressure. It is a net pressure.

• If the oil pump is selected to be a part time oil pump in the “Setup” menu, then ensure that it only shuts off at an appropriate pressure ration that takes into account pressure drops through the oil cooler. This is a set point in the “Compressor Control Setpoints” menu called “Oil Pump Restart.” It is a pressure ratio. (discharge pressure in psia/suction pressure in psia) Default ratio is a pressure ratio of 3.00:1 that stops the pump and 2.80:1 that restarts the pump. This ratio can be increased. Do not decrease without consulting Vilter.

• Clean oil strainer screen.

• Change oil ﬁ lter, maybe plugged or collapsed.

• Oil pump gears worn internally, excessive end-clearance.

• Oil priming valve used on air-cooled cooler units is open.

• Relief in-line check valve stuck open.

• Pressure ratio too low, oil pump should be on.

• Check that the correct pressure or temperature range is selected in the Instrument Calibration menu.

Faulty pressure or temperature readings

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

• Check cable connections at device, terminal strips, and PLC input card for correct wiring and shielding (RF noise).

• Check calibration of RTDs and transducers.

6 – 5

Section 6 • Troubleshooting

Table 6-3. Troubleshooting Guide - General Problems & Solutions (2 of 3)

Problem Solution

• Oil return line from coalescing side of oil separator to suction is closed, not open enough (.75 turns should be sufﬁ cient), or plugged with debris

• The check valve in the oil return line could be stuck closed or the ﬂ ow is in the wrong direction

• There may be water in the oil affecting the coalescing elements

• Coalescent elements in need of replacement due to age or damage (water

Oil Loss Issues

High oil temperature (liquid injection)

Capacity/Volume Slide Actuator Alarms/Trips/ Symptoms:

contamination)

• The operating conditions are not correct (too high of suction and/or too low discharge pressure) This creates increased gas ﬂ ow which could make the oil separator too small

• The suction or discharge check valve is not working correctly causing oil to escape when the unit stops

• Viscosity of oil incorrect; send sample for testing

• There is an oil leak somewhere in the system

• Check for correct setting of all manual values.

• Check for correct operation of 2-way automatic oil mixing valve.

• In the “Vilter Only” menu, ensure that you select “Yes this unit has the oil mixing valve” to enable it.

• If your are controlling a step type oil cooler or a VFD oil cooler, verify the correct one is selected in the “Vilter Only” menu and the amount of steps are entered in the menu screen “Oil Cooler Step Control” menu.

• Check the oil cooler and associated piping to make sure it is full of oil before starting.

• Check the oil strainer for debris and clean if necessary.

• Verify that the volume slide actuator is functioning correctly and that the correct compressor size (type) is selected in the “Vilter Only” menu.

• Check that all fans are working.

• Check for correct fan rotation on the oil cooler.

• Check that your operating conditions are within the “As Sold” design conditions.

• Calibration method not correct

• Actuator or Gear motor not working, or off on overload

• Slide valve carriage assembly out of position, slides binding

• Cross-shaft gears, broken pins

• Command shaft broken

• Slide valve rack or rack shaft damaged

• Check balance piston movement

• Reference Slide Valve Actuator Troubleshooting Guide

• Check I/O fusing

6 – 6

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 6 • Troubleshooting

Table 6-3. Troubleshooting Guide - General Problems & Solutions (3 of 3)

Problem Solution

High Amp Draw • Check Main Motor Amps scaling and PLC.

• Check that unit is leveled and secured to mounting pad or ﬂ oor.

• Check supported pipes (i.e. suction and discharge pipe) and make sure they

Vibration

are adequately supported.

• Check for loose bolts and nuts.

• Check condition of compressor and motor (i.e. alignments)

Excessive Motor Backspin

• If there is more than normal motor backspin at shutdown, check suction check valve for proper operation.

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6 – 7

6 – 8 / Blank

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Section 7 • Warranty and Parts

Warranty Claim Processing

This section explains how the warranty claim is processed and to help clear any questions that may arise prior to contacting customer service. For additional warranty information, refer to the VSG/VSSG Standard Vilter Warranty Statement on page i. Vilter contact information can be found on page ii.

1. The warranty process starts with contacting a Vilter Service and Warranty (S&W) department representative. Ensure to have the original Vilter sales order

number for the equipment available to better assist you.

2. Our Vilter S&W representative will conﬁ rm if the equipment is within the warranty time frame as described in the warranty statement.

If the equipment (Part/Compressor/Compressor Motor) is within the warranty time frame, proceed to the following section regarding the type of equipment:

PAR T

1. Submit a Purchase Order (PO) to procure the replacement part:

• The correct Vilter part number and the quantity.

• The original Vilter sales order for the equipment.

2. Request a Return Material Authorization (RMA) number:

• Please provide as much information describing the mode of failure to be recorded on the RMA document. This will assist us with providing a quicker review once we have received the warranty part (ex. Part does not calibrate, part does not read correct temperature, etc.).

• Any additional parts returned on the RMA that is not listed, will be returned freight collect or scrapped. The RMA is valid for 60 days from the RMA request date.

3. After replacing the warranty part:

• Ship the part to Vilter per the instructions on the RMA document.

• Please include a copy of the RMA document in the box for identiﬁ cation purposes when the part is received.

4. Part to be evaluated.

5. Warranty Consideration:

• Acceptance – A credit will be provided for the customer part sales order.

• Denial – Notiﬁ cation of denial will be provid- ed to the customer.

COMPRESSOR

• Due to the site speciﬁ c nature of compressor warran- ty, all warranty responses must be mitigated through a Vilter S&W department representative.

COMPRESSOR MOTOR

The warrany is a pass through warranty as stated in the equipment warranty and as such will be determined by the manufacturer. All extraneous expenses (i.e. shipping,

removal/installation, alignment) are not covered by Vilter’s nor the manufacturer’s warranty.

1. The motor will need to be taken to the nearest

Electrical Apparatus Service Association (EASA) repair facility or motor manufacturer approved repair facility.

2. The motor shop will provide the motor manufac-

turer with the failure analysis.

3. The motor manufacturer will make the warranty

disposition.

On Site Service Support

If on site support is required, contact a Vilter S&W department representative to start this process.

Warranty does not cover labor and extraneous expenses.

1. A quote, a service rate sheet, and the service terms

and conditions will be provided.

2. Submit a PO.

3. Schedule the service visit.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

7 – 1

Section 7 • Warranty and Parts

Remanufactured Gas Bare Shaft Compressor Process

These instructions are an overview of how the process works when a bare shaft compressor is in need of being remanufactured. This is to help clear any questions that may arise prior to contacting customer service.

The process begins by contacting Vilter’s Customer Service Department. Vilter contact information can be found on page ii.

• Request a “VSG Single Screw Compressor Rebuild Form”.

• Submit the Rebuild Form and a Purchase Order (PO) for the inspection. A fee is required for the initial inspection and teardown report; contact Vilter Customer Service representative for the latest fee.

• A Return Material Authorization (RMA) number will be provided.

• Send the compressor to Vilter in the condition as stated on the Rebuild Form (i.e. no oil in the compressor). Charges may apply if conditions are not met.

• A report will be sent to you after the inspection has been completed explaining what level of rebuild is necessary along with the cost.

NOTE

Inspection and rebuild times will vary, contact Vilter

Customer Service representative for further details.

• Submit a new PO for the amount that will be needed for the rebuild. The inspection cost will be waived upon receipt of the new PO. Make sure to provide your “Ship to Address” and “Billing Address”.

Level 3 - Current Reman Compressor requires complete rebuilding and re-conditioning to “as-new” condition. All the components listed in Level 2 are replaced plus all hardware, slide assemblies, pistons, and a main rotor (if damaged) and/or gate rotor supports.

NOTE

A Level 1 and Level 2 rebuild will include washing the housing and repainting over the current paint. A Level 3 rebuild will include blasting all the current

paint off before repainting.

BARE SHAFT COMPRESSOR DESCRIPTION

Single Screw Bare Shaft Compressor features include:

• Cast grey iron frame with cast ductile iron discharge manifold and gate rotor covers with discharge connection horizontal.

• Standard drive shaft is tapered.

• Standard slide assembly.

• Viton shaft seal O-rings.

• Crating with Purge & Gauge.

• Does not include handwheels or slide valve motors.

EXPLANATION OF REBUILD LEVELS

Level 1

Compressor is in good condition. Replace bearings, gaskets, shaft seal and o-rings. All hardware is intended to be re-used (when possible). Parts are organized in part kit form.

Level 2

Compressor is in good condition, but requires new gate rotor blades. Replace all items in Level 1 plus new gate rotor blades and bushings.

7 – 2

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Appendix A • Torque Specifications

Torque Specifications (ft-lbs)

Type

Bolt

SAE Grade 2

Coarse (UNC)

SAE Grade 5

Coarse (UNC)

SAE Grade 5

Coarse (UNC)

SAE Grade 8

Coarse (UNF)

Socket Head

Cap Screw

(ASTM A574)

Coarse (UNC)

1) Torque values in this table are not to override other speciﬁ c torque speciﬁ cations when supplied.

2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after loctite is applied.

* The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less than smaller sizes of the same grade.

Head

Markings

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

- 5 10 18 29 44 63 87 155 150*

- 8 16 28 44 68 98 135 240 387

--18-------

- 11 22 39 63 96 138 191 338 546

5 13 26 46 73 112 115 215 380 614

Nominal Size Numbers or Inches

Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs)

Type

Bolt/Nut

Hex & Socket

Head Cap Screws

Nut -8-25-----

NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243 (VPN 2205F or 2205G) on all remaining locations.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Head

Markings

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

3 8 14 25 40 60 101 137 245

Nominal Size Numbers or Inches

Appendix B • Motor (Compressor) - General Storage Instructions

Short Term Storage

If the equipment is not put into immediate use it should be stored in a clean, dry location. For all Weather Protected Type II (WPII) motors, motor heaters should be activated upon arriving at the jobsite to prevent condensation. This is required for warranty considerations.

Care should be taken to keep the equipment covered when moving from a cold location to a warm location, otherwise condensation may occur. If condensation does occur, and the equipment is moist, allow it to dry thoroughly before applying power.

Long Term Storage

1. Cover machined metal parts with weatherproof cover, but leave ventilating area exposed.

2. Make certain unpainted portions are covered and retouch any scratches or ﬂ aked areas.

3. If condensate plugs or drain plugs have been used, make sure they are operative.

4. Cover completely with plastic cover and insert silicagel bags inside the cover for moisture control.

5. If motor is equipped with space heaters make sure space heaters are properly connected and operative. The motor interior temperature should be maintained approximately 10 °F (5.6 °C) above ambient.

6. For all Weather Protected Type II (WPII) motors, motor heaters should be activated upon arriving at the jobsite to prevent condensation. This is required for warranty

considerations.

7. A systematic inspection and maintenance schedule should be established. If rotating apparatus is to be stored for 6 months or longer, it should, in addition to the minor precautions above, be given a megger test every 3 to 6 months. A minimum reading of 10 megohoms is recommended. A record of insulation values, temperature, time, humidity and length of voltage application should be recorded to show winding conditions prior to start up.

8. If windings are designed for outdoor operation, they will not be affected by extreme or sudden temperature changes or inclement weather in general. However a weather proof cover with provisions for adequate ventilation should be used to guard against intrusion of salt, dust, or other abrasive or corrosive material.

9. It is recommended that the rotor be turned every month to redistribute the lubricant in the bearings and oil or grease be added every 6 six months.

10. Preferably, storage would be in a warehouse or enclosed building but the same precautions should be followed.

Lubrication

Refer to manufacturer’s lubrication instructions.

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

Emerson VSG, VSSG User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents